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<p>In the nuclear industry, achieving high-quality welds requires careful study of the formation of the fusion zone (FZ) and heat-affected zone (HAZ), as these regions play a critical role in determining the joint’s metallurgical and mechanical properties. Accurate characterisation of the FZ and HAZ depends on understanding the transient temperature distribution during welding. In this work, a multiphysics finite element model incorporating a moving heat source was developed to efficiently simulate the Tungsten inert gas welding process. The influence of welding current, arc distance and rotational speed on thermal profiles was systematically investigated. The simulations predicted that the FZ and HAZ lengths varied from 0.6 to 2.0&#xa0;mm and from 2.95 to 5.4&#xa0;mm, respectively, depending on the welding parameters. These predictions showed good agreement with experimental measurements, with deviations within 10%. Numerical predictions were validated through microstructural analysis, which confirmed a close agreement between the simulated temperature fields and the experimentally observed microstructure. The FZ exhibited Widmanstätten structures that gradually transitioned into equiaxed grains in the parent metal. The hardness profiles were consistent with these microstructural variations, with maximum values of approximately 220 HV in the Widmanstätten region and a gradual decrease to about 160 HV in the base material. Furthermore, EBSD analysis revealed random grain orientations in the FZ due to the β → α phase transformation, whereas the parent material retained a strong basal texture resulting from the pilgering process.</p>

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Numerical simulation of temperature distribution and microstructural correlation in TIG welded Zircaloy-2 fuel pin joints

  • 期刊论文

  • 发表日期：

    2026年4月29日

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  • Shibashankar Das,
  • Mani Krishna K. V.,
  • Raghvendra Tewari

摘要

In the nuclear industry, achieving high-quality welds requires careful study of the formation of the fusion zone (FZ) and heat-affected zone (HAZ), as these regions play a critical role in determining the joint’s metallurgical and mechanical properties. Accurate characterisation of the FZ and HAZ depends on understanding the transient temperature distribution during welding. In this work, a multiphysics finite element model incorporating a moving heat source was developed to efficiently simulate the Tungsten inert gas welding process. The influence of welding current, arc distance and rotational speed on thermal profiles was systematically investigated. The simulations predicted that the FZ and HAZ lengths varied from 0.6 to 2.0 mm and from 2.95 to 5.4 mm, respectively, depending on the welding parameters. These predictions showed good agreement with experimental measurements, with deviations within 10%. Numerical predictions were validated through microstructural analysis, which confirmed a close agreement between the simulated temperature fields and the experimentally observed microstructure. The FZ exhibited Widmanstätten structures that gradually transitioned into equiaxed grains in the parent metal. The hardness profiles were consistent with these microstructural variations, with maximum values of approximately 220 HV in the Widmanstätten region and a gradual decrease to about 160 HV in the base material. Furthermore, EBSD analysis revealed random grain orientations in the FZ due to the β → α phase transformation, whereas the parent material retained a strong basal texture resulting from the pilgering process.