Numerical simulation method of submerged arc surfacing process of rollers

The submerged arc surfacing process involves complex behaviors such as metal heat transfer, melting, flow, phase transformation, and solidification and involves the interaction of electric field, thermal field, magnetic field, and flow field. At present, it is impossible to reveal the transient mechanism of multi-field coupling in submerged arc surfacing by experience or trial and error, which is not conducive to shorten the development cycle and save the cost. Moreover, it is difficult to measure the molten pool velocity, von Mises stress, and phase transformation zone in real-time. However, these factors are the key to obtain a high-quality surfacing layer. Therefore, a three-dimensional mathematical model of heat force flow multi-field coupling for roller submerged arc surfacing is established in this article. The distribution and variation of welding temperature, von Mises stress, molten pool flow field, and phase transformation zone are revealed by solving the model. The maximum von Mises stress of the rollers during submerged arc surfacing is 432 MPa. The depth of the phase transformation is 2.50 mm, and the width is 1.98 mm. Zeiss-IGMA HD FESEM was used to observe the welding microstructure. The results show that the main microstructure is martensite and a small amount of ferrite.