Main Article Content
Flash butt welding is a resistance type metal joining process designed to produce butt welds between two materials of similar cross sections. The primary objective of this study was to develop numerical simulation technique for prediction of temperature histories in flash butt welded bars. Welding process variables that affect temperature which were examined include; pre-heat, boundary convection severity, flash duration and material properties. Temperature profile plots were along the longitudinal and radial directions of the bar. The effect of nodal densities on temperature values at a point was examined. Finite element software ANSYS 16.0 was used to solve the quasi-linear thermal transient equation. Non-uniform plane77 mesh size was used in order to allow for higher concentration of nodes around the heat affected zone (HAZ). Applying a bar diameter of 25 mm, length 250 mm and flash duration of 4 seconds, indicated peak temperature values were 1400, 1238.9, 910.18 and 650.68 0C at distances 0, 1, 3 and 5 mm from the weld flash line. Peak temperatures generally increased with increased pre-heat condition and flash duration. Simulated peak temperatures were compared with weld temperature results of other related works and close correlations were observed.
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