Modeling of Gas Metal Arc Welding Process Using an Analytically Determined Volumetric Heat Source

Abstract

High peak temperature and continuous deposition of electrode droplets in the weld puddle inhibit realtime monitoring of thermal cycles and bead dimensions in gas metal arc welding. A three-dimensional numerical heat transfer model is presented here to compute temperature field and bead dimensions considering a volumetric heat source to account for the transfer of arc energy into the weld pool. The heat source dimensions are analytically estimated as function of welding conditions and original joint geometry. The deposition of electrode material is modeled using deactivation and activation of discrete elements in a presumed V-groove joint geometry. The computed values of bead dimensions and thermal cycles are validated with the corresponding measured results. A comparison of the analytically estimated heat source dimensions and the corresponding numerically computed bead dimensions indicate that the former could rightly serve as the basis for conduction heat transfer based models of gas metal arc welding process.

Numerical modelling of gas metal arc joining of aluminium alloy and galvanised steels in lap joint configuration

“…Similar studies to analytically estimate the bead profile are reported earlier for butt joint configuration. 37, 38 In contrast, the filler wire deposit profile in lap joint of aluminium to steel will be governed by the melting of aluminium sheet and filler wire, and the spread of molten filler over the unmelted steel surface. Figure 2 shows a presumed cross-section of the filler wire deposit profile encompassed by four line segments , , and , and the circular arc BED.…”

Numerical Analysis on Thermal Characteristics of Direct Current Pulsed Gas Metal Arc Welded Joints of AA5052 Aluminum Alloy to DP590 High Strength Steel

“…Several studies estimating the bead profiles for butt and lap joint configuration indicate the bead dimension in lap joint is decided by deposition of molten filler wire and aluminum base metal, and the spread of molten filler to the steel surface. [13,14] The dimension of wire deposited bead profile is presumed as Fig. 2.…”