This article analyzes the transient complex heat transfer and fluid flow in molten metal and arc plasma during the gas metal arc welding process. The model predicts the formation, growth, detachment, and transfer of droplets from the tip of a continuously fed electrode under the influences of several competing forces including gravity, electromagnetic force, arc pressure, plasma shear stress, and surface tension. Simulations were conducted for five different current levels to study the effects of current on the distributions of temperature, velocity, pressure, and current density in the droplet and/or the arc plasma. Agreement between the simulated results and published experimental data was obtained.
Issue Section:
Heat Transfer in Manufacturing
1.
Kim
, C. H.
, Zhang
, W.
, and DebRoy
, T.
, 2003, “Modeling of Temperature Field and Solidified Surface Profile During Gas-Metal Arc Fillet Welding
,” J. Appl. Phys.
0021-8979, 94
, pp. 2667
–2679
.2.
AWS
, 1983, Welding Handbook
, 7th ed., American Welding Society
, Vol. 2
.3.
Lin
, Q.
, Li
, X.
, and Simpson
, S. W.
, 2001, “Metal Transfer Measurements in Gas Metal Arc Welding
,” J. Phys. D
0022-3727, 34
, pp. 347
–353
.4.
Jones
, L. A.
, Eagar
, T. W.
, and Lang
, J. H.
, 1998, “Images of Steel Electrode in Ar‐2%O2 Shielding during Constant Current Gas Metal Arc Welding
,” Weld. J. (Miami, FL, U.S.)
0043-2296, 77
, pp. 135
–141s
.5.
Jones
, L. A.
, Eagar
, T. W.
, and Lang
, J. H.
, 1998, “Magnetic Forces Acting on Molten Drops in Gas Metal Arc Welding
,” J. Phys. D
0022-3727, 31
, pp. 93
–106
.6.
Jones
, L. A.
, Eagar
, T. W.
, and Lang
, J. H.
, 1998, “A Dynamic Model of Drops Detaching from a Gas Metal Arc Welding Electrode
,” J. Phys. D
0022-3727, 31
, pp. 107
–123
.7.
Simpson
, S. W.
, and Zhu
, P. Y.
, 1995, “Formation of Molten Droplets at a Consumable Anode in an Electric Welding Arc
,” J. Phys. D
0022-3727, 28
, pp. 1594
–1600
.8.
Nemchinsky
, V. A.
, 1994, “Size and Shape of the Liquid Droplet at the Molten Tip of an Arc Electrode
,” J. Phys. D
0022-3727, 27
, pp. 1433
–1442
.9.
Choi
, J. H.
, Lee
, J.
, and Yoo
, C. D.
, 2001, “Dynamic Force Balance Model for Metal Transfer Analysis in Arc Welding
,” J. Phys. D
0022-3727, 34
, pp. 2658
–2664
.10.
Lancaster
, J. F.
, 1986, The Physics of Welding
, 2nd ed., Pergamon
, Oxford.11.
Zhang
, Y. M.
, and Liguo
, E.
, 2000, “Numerical Analysis of the Dynamic Growth of Droplets in Gas Metal Arc Welding
,” Proc. Inst. Mech. Eng., Part C: J. Mech. Eng. Sci.
0954-4062, 214
Part C, pp. 1247
–1258
.12.
Zhang
, Y. M.
, and Li
, P. J.
, 2001, “Modified Active Control of Metal Transfer and Pulsed GMAW of Titanium
,” Weld. J. (Miami, FL, U.S.)
0043-2296, 80
, pp. 54
–61s
.13.
Fan
, H. G.
, and Kovacevic
, R.
, 1998, “Dynamic Analysis of Globular Metal Transfer in Gas Metal Arc Welding: A Comparison of Numerical and Experimental Results
,” J. Phys. D
0022-3727, 31
, pp. 2929
–2941
.14.
Choi
, S. K.
, Yoo
, C. D.
, and Kim
, Y. S.
, 1998, “The Dynamic Analysis of Metal Transfer in Pulsed Current Gas Metal Arc Welding
,” J. Phys. D
0022-3727, 31
, pp. 207
–215
.15.
Choi
, S. K.
, Kim
, Y. S.
, and Yoo
, C. D.
, 1999, Dimensional Analysis of Metal Transfer in GMA Welding
,” J. Phys. D
0022-3727, 32
, pp. 326
–334
.16.
Choi
, S. K.
, Yoo
, C. D.
, and Kim
, Y. S.
, 1998, “Dynamic Simulation of Metal Transfer in GMAW, Part 1: Globular and Spray Transfer Modes
,” Weld. J. (Miami, FL, U.S.)
0043-2296, 77
, pp. 38
–44s
.17.
Choi
, S. K.
, Yoo
, C. D.
, and Kim
, Y. S.
, 1998, “Dynamic Simulation of Metal Transfer in GMAW, Part 2: Short-Circuit Transfer Mode
,” Weld. J. (Miami, FL, U.S.)
0043-2296, 77
, pp. 45
–51s
.18.
Wang
, G.
, Huang
, P. G.
, and Zhang
, Y. M.
, 2003, “Numerical Analysis of Metal Transfer in Gas Metal Arc Welding under Modified Pulsed Current Conditions
,” Metall. Mater. Trans. B
1073-5615, 35B
, pp. 857
–866
.19.
Zhu
, P.
, Rados
, M.
, and Simpson
, S. W.
, 1995, “A Theoretical Study of Gas Metal Arc Welding System
,” Plasma Sources Sci. Technol.
0963-0252, 4
, pp. 495
–500
.20.
Wang
, F.
, Hou
, W. K.
, Hu
, S. J.
, Kannatey-Asibu
, E.
, Schultz
, W. W.
, and Wang
, P. C.
, 2003, “Modelling and Analysis of Metal Transfer in Gas Metal Arc Welding
,” J. Phys. D
0022-3727, 36
, pp. 1143
–1152
.21.
Fan
, H. G.
, and Kovacevic
, R.
, 1999, “Droplet Formation, Detachment, and Impingement on the Molten Pool in Gas Metal Arc Welding
,” Metall. Mater. Trans. B
1073-5615, 30B
, pp. 791
–801
.22.
Haidar
, J.
, and Lowke
, J. J.
, 1996, “Predictions of Metal Droplet Formation in Arc Welding
,” J. Phys. D
0022-3727, 29
, pp. 2951
–2960
.23.
Haidar
, J.
, 1998, “An Analysis of the Formation of Metal Droplets in Arc Welding
,” J. Phys. D
0022-3727, 31
, pp. 1233
–1244
.24.
Haidar
, J.
, 1998, “A Theoretical Model for Gas Metal Arc Welding and Gas Tungsten Arc Welding. I
,” J. Appl. Phys.
0021-8979, 84
, pp. 3518
–3529
.25.
Haidar
, J.
, 1998, “Prediction of Metal Droplet Formation in Gas Metal Arc Welding II
,” J. Appl. Phys.
0021-8979, 84
, pp. 3530
–3540
.26.
Haidar
, J.
, 1998, “An Analysis of Heat Transfer and Fume Production in Gas Metal Arc Welding. III.
,” J. Appl. Phys.
0021-8979, 85
, pp. 3448
–3459
.27.
Zhu
, F. L.
, Tsai
, H. L.
, Marin
, S. P.
, and Wang
, P. C.
, 2004, “A Comprehensive Model on the Transport Phenomena during Gas Metal Arc Welding Process
,” Prog. Comput. Fluid Dyn.
1468-4349, 4
, pp. 99
–117
.28.
Fan
, H. G.
, and Kovacevic
, R.
, 2004, “A Unified Model of Transport Phenomena in Gas Metal Arc Welding including Electrode, Arc Plasma and Molten Pool
,” J. Phys. D
0022-3727, 37
, pp. 2531
–2544
.29.
Subramaniam
, S.
, White
, D. R.
, Scholl
, D. J.
, and Weber
, W. H.
, 1998, “In Situ Optical Measurement of Liquid Drop Surface Tension in Gas Metal Arc Welding
,” J. Phys. D
0022-3727, 31
, pp. 1963
–1967
.30.
Wang
, Y.
, and Tsai
, H. L.
, 2001, “Impingement of Filler Droplets and Weld Pool Dynamics During Gas Metal Arc Welding Process
,” Int. J. Heat Mass Transfer
0017-9310, 44
, pp. 2067
–2080
.31.
Wang
, Y.
, and Tsai
, H. L.
, 2001, “Effects of Surface Active Elements on Weld Pool Fluid Flow and Weld Penetration in Gas Metal Arc Welding
,” Metall. Mater. Trans. B
1073-5615, 32B
, pp. 501
–515
.32.
Hu
, J.
, 2005, “Heat and Mass Transfer in the Gas Metal Arc Welding Process
,” Ph.D. dissertation, University of Missouri-Rolla, Rolla, MO.33.
Chiang
, K. C.
, and Tsai
, H. L.
, 1992, “Shrinkage Induced Fluid Flow and Domain Change in Two-Dimensional Alloy Solidification
,” Int. J. Heat Mass Transfer
0017-9310, 35
, pp. 1763
–1770
.34.
Carman
, P. C.
, 1937, “Fluid Flow Through Granular Beds
,” Trans. Inst. Chem. Eng.
0371-7496, 15
, pp. 150
–166
.35.
Kubo
, K.
, and Pehlke
, R. D.
, 1985, “Mathematical Modeling of Porosity Formation in Solidification
,” Metall. Trans. A
0360-2133, 16A
, pp. 823
–829
.36.
Beavers
, G. S.
, and Sparrow
, E. M.
, 1969, “Non-Darcy Flow through Fibrous Porous Media
,” ASME J. Appl. Mech.
0021-8936, 36
, pp. 711
–714
.37.
Lowke
, J. J.
, Kovitya
, P.
, and Schmidt
, H. P.
, 1992, “Theory of Free-Burning Arc Columns Including the Influence of the Cathode
,” J. Phys. D
0022-3727, 25
, pp. 1600
–1606
.38.
Zacharia
, T.
, David
, S. A.
, and Vitek
, J. M.
, 1992, “Effect of Evaporation and Temperature-Dependent Material Properties on Weld Pool Development
,” Metall. Trans. B
0360-2141, 22B
, pp. 233
–241
.39.
Jonsson
, P. G.
, Westhoff
, R. C.
, and Szekely
, J.
, 1993, “Arc Characteristics in Gas-Metal Arc Welding of Aluminum Using Argon as the Shielding Gas
,” J. Appl. Phys.
0021-8979, 74
, pp. 5997
–6006
.40.
Torrey
, M. D.
, Cloutman
, L. D.
, Mjolsness
, R. C.
, and Hirt
, C. W.
, 1995, “NASA-VOF2D: A Computer Program for Incompressible Flows with Free Surfaces
,” LA-10612-MS, Los Alamos National Laboratory.41.
Brackbill
, J. U.
, Kothe
, D. B.
, and Zemach
, C.
, 1992, “A Continuum Method for Modeling Surface Tension
,” J. Comput. Phys.
0021-9991, 100
, pp. 335
–354
.42.
Celic
, A.
, and Zilliac
, G. G.
, 1997, “Computational Study of Surface Tension and Wall Adhesion Effects on an Oil Film Flow Underneath an Air Boundary Layer
,” Nasa Ames Research Center.43.
Granger
, R. A.
, 1995, Fluid Mechanics
, CBS College
, New York, Chap. 10.44.
Patanka
, S. V.
, 1980, Numerical Heat Transfer and Fluid Flow
, McGraw-Hill
, New York.45.
Nemchinsky
, V. A.
, 1996, “The Effect of the Type of Plasma Gas on Current Constriction at the Molten Tip of an Arc Electrode
,” J. Phys. D
0022-3727, 29
, pp. 1202
–1208
.Copyright © 2007
by American Society of Mechanical Engineers
You do not currently have access to this content.
