Numerical Simulations Based on a Meshfree Method for Nickel-Steel Welded Joint Manufactured by Micro-Jet Cooling

Abstract

The article presents a numerical–experimental approach to the weldability and mechanical resistance of the joint of Alloy 59 (2.4605, nickel-chromium-molybdenum) and S355J2W (1.8965) structural steel manufactured by the MIG process with the use of micro-jet cooling. This research was considered because the standard MIG process does not guarantee the procurement of a mixed hard-rusting structural steel superalloy weld of a repeatable and acceptable quality. Welds made through the classic MIG process express cracks that result from their unfavorable metallographic microstructure, while the joint supported by micro-jet cooling does not reflect any cracks and has a high strength with good flexibility. This was achieved by the application of helium for cooling. The joining technology was also considered in the numerical stage, represented by calculations in situ. For this purpose, the fundamental solution method (FSM) for the simulation of heat transfer during the process of welding with micro-jet cooling was implemented according to the initial boundary value problem (IBVP). The problem was solved employing the method of combining the finite difference method, Picard iterations, approximation by the radial basis function, and the fundamental solution method so as to solve the IVBP. The proposed method was validated by the data and results obtained during in situ experiments. The numerical approach enabled us to obtain variations in the temperature distribution values in HAZ with its different dimensional variants, ranging between 600 °C and 1400 °C.