Simulation of the mode of electron-beam welding of a thin-wall structure from AD31 alloy

The article contains the results obtained by the authors in the study of the possibility of using electron beam welding (EBW) for thin-walled structures made of AD31 aluminum alloy. Today, EBW of similar designs are not used due to the lack of technology. Currently, other technologies for connecting similar structures are used in production, but they have a high cost, the reason for which is due to the high percentage of defects. The method of using EBW proposed by the authors will significantly improve the quality of the joint in thin-walled structures and the reproducibility of the technological mode of welding products. The authors have developed a technological solution to the presented problem, based on many years of experience in the use of models of thermal processes, accompanied by electron beam welding. As a subject of research, modeling of the parameters of electron-beam welding of thin-walled pipes for waveguide paths made of aluminum alloy AD31 is proposed. The article presents the results of mathematical modeling of technological parameters during heating of an aluminum alloy by energy sources equivalent to an electron beam during EBW. The analysis and evaluation of the simulation results was carried out using the optimality criterion developed by the authors. The calculations performed by the authors are based on functional using mathematical models of metal heating by a complex heat source consisting of moving instantaneous point and linear energy sources. The article presents the results of calculations for a plate with a thickness of 0.12 cm, which corresponds to prototypes used in the manufacture of waveguide paths. As a result, by changing such values as: beam current and welding speed, the temperature distribution on the surface of the product during the EBW process was obtained, which showed the applicability of modeling for developing a new technological process.