Simulation of Gas Metal Arc Welding Short Circuiting Transfer Using a Front Tracking Method

Manufacturing ◽  
2002 ◽  
Author(s):  
Guo Xu ◽  
Elijah Kannatey-Asibu ◽  
William W. Schultz ◽  
P. C. Wang
Keyword(s):  
Shear Stress ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Current ◽  
Front Tracking ◽  
Front Tracking Method ◽  
Metal Arc Welding ◽  
Initial Drop ◽  
Velocity Pressure ◽  
First Time

A numerical model is developed to simulate the short-circuiting metal transfer process during gas metal arc welding (GMAW). To our best knowledge, for the first time, the energy equation is considered in analyzing the short-circuiting time, along with the continuity and momentum equations. A front tracking free surface method is implemented to explicitly track the profile of the liquid bridge. The electromagnetic field, distribution of velocity, pressure, and temperature are calculated using the developed model. Effects of welding current, Marangoni shear stress and initial drop volume on short-circuiting duration time are examined. The results show that both the electromagnetic force and Marangoni shear stress play significant roles in the short-circuiting transfer.

Application of a Front Tracking Method in Gas Metal Arc Welding (GMAW) Simulation

2004 ◽  
Vol 127 (3) ◽  
pp. 590-597 ◽  
Author(s):  
Guo Xu ◽  
William W. Schultz ◽  
Elijah Kannatey-Asibu
Keyword(s):  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Current ◽  
Front Tracking ◽  
Front Tracking Method ◽  
Surface Method ◽  
Metal Arc Welding ◽  
Initial Drop ◽  
Velocity Pressure ◽  
First Time

A numerical model is developed to simulate the short-circuiting metal transfer process during gas metal arc welding (GMAW). The energy equation and the Marangoni convection are considered for the first time in analyzing the short-circuiting time. A front-tracking free surface method explicity tracks the profile of the liquid bridge. The electromagnetic field, distribution of velocity, pressure, and temperature are calculated using the developed model. Effects of welding current, surface tension temperature coefficient, and initial drop volume on short-circuiting duration time are examined. The results show that both the electromagnetic force and Marangoni shear stress play significant roles in short-circuiting transfer welding.

Modeling of Metal Transfer in Short Circuiting Arc Welding

2004 ◽  
Author(s):  
Guo Xu ◽  
William W. Schultz ◽  
Elijah Kannatey-Asibu ◽  
S. Jack Hu ◽  
Pei-Chung Wang
Keyword(s):  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Marangoni Effect ◽  
Welding Current ◽  
Metal Transfer ◽  
Vof Model ◽  
Metal Arc Welding ◽  
Method Effects ◽  
Velocity Pressure ◽  
First Time

The short-circuiting metal transfer during gas metal arc welding (GMAW) is simulated by a numerical model. To the best of our knowledge, for the first time the energy equation and the Marangoni convection are considered in analyzing the short-circuiting time. A front-tracking free surface method is applied to explicitly track the bridge profile. To benchmark this method, effects of the density and viscosity ratios between different phases are investigated by simulating a drop driven by surface tension. The temporal profile of the drop is compared to that computed by a Volume of Fluid (VOF) model, and very good agreement is found. The model is then applied to simulate GMAW short-circuiting transfer. The velocity, pressure, temperature and electromagnetic fields are calculated. Effects of welding current and Marangoni shear stress on short-circuiting time are examined. It is shown that the Marangoni effect plays an important role in GMAW short-circuiting transfer.

Investigation on arc light intensity in gas metal arc welding. Part 1: Relationship between arc light intensity and arc length

1997 ◽  
Vol 211 (5) ◽  
pp. 345-353 ◽  
Author(s):  
C D Yoo ◽  
Y S Yoo ◽  
H-K Sunwoo
Keyword(s):  
Light Intensity ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Current ◽  
Arc Length ◽  
Metal Arc Welding ◽  
Proposed Model ◽  
Welding Part ◽  
The Relationship ◽  
Good Agreement

The arc length has been detected through the arc because the welding current and voltage vary linearly with the arc length. In this work, the relationship between the arc light intensity and arc length is investigated through analytic modelling. The arc light intensity is derived as a function of the arc length and welding current using the heat balance in the plasma. Experiments are carried out to verify the proposed model and to find out the effects of welding conditions on the arc light intensity in gas metal arc welding (GMAW). The arc light intensity varies proportionally to the arc length and signal quality is enhanced with a fast weaving speed. The predicted results of the arc light intensity show reasonably good agreement with the experimental data.

Influence of Preset Pulsed Magnetic Field on Process Stability of Short Circuiting Transfer in Gas Metal Arc Welding

2011 ◽  
Vol 339 ◽  
pp. 440-443 ◽  
Author(s):  
Shu Jun Chen ◽  
Chang Hui Liu ◽  
Yang Yu ◽  
Shao Jun Bai
Keyword(s):  
Magnetic Field ◽  
Arc Welding ◽  
Short Circuit ◽  
Gas Metal Arc Welding ◽  
Welding Current ◽  
Pulsed Magnetic Field ◽  
Optimum Conditions ◽  
Horizontal Magnetic Field ◽  
Metal Arc Welding ◽  
Peak Value

This study proposed preset pulsed magnetic field acting on process of the short circuiting transfer. It is a controlled horizontal magnetic field which attached at the very beginning of contact between the wire and the weld pool during welding. It was found that there exists optimum conditions of magnetic field with which preset pulsed magnetic field could accelerate the rupture of the liquid bridge and reduce the peak value of welding current in the period of short circuiting transfer. This lead to energy accumulation lowered at the last phase of the short circuiting transfer and spatter loss reduced resulting from explosive short circuit rupture, in the meantime, it could improve the regularity and stability of the short circuiting transfer as well as the weld shaping quality.

scholarly journals Development of Digital Gas Metal Arc Welding System and Welding Current Control Using Self-tuning Fuzzy PID

2011 ◽  
Vol 25 (6) ◽  
pp. 1-8
Author(s):  
Phuc Thinh Doan ◽  
Pandu Sandi Pratama ◽  
Suk-Yoel Kim ◽  
Hak-Kyeong Kim ◽  
Hwang-Yeong Yeun ◽  
...  
Keyword(s):  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Current ◽  
Current Control ◽  
Fuzzy Pid ◽  
Metal Arc Welding ◽  
Self Tuning ◽  
Welding System

scholarly journals Globular-to-Spray Transition in Cold Wire Gas Metal Arc Welding

2021 ◽  
Vol 100 (4) ◽  
pp. 121-131
Author(s):  
R. A. RIBEIRO ◽  
◽  
P. D. C. ASSUNÇÃO ◽  
E. B. F. DOS SANTOS ◽  
E. M. BRAGA ◽  
...  
Keyword(s):  
Arc Welding ◽  
High Speed ◽  
Gas Metal Arc Welding ◽  
Welding Current ◽  
Electrical Current ◽  
Feed Speed ◽  
High Speed Imaging ◽  
Transition Mechanism ◽  
Cold Wire ◽  
Metal Arc Welding

The electrical current required for a transition from globular to spray droplet transfer during gas metal arc welding (GMAW) is determined by the specified wire feed speed in the case of constant-voltage power supplies. Generally, in narrow groove welding, spray transfer is avoided, be-cause this transfer mode can severely erode the groove sidewalls. This work compared the globular-to-spray transition mechanism in cold wire gas metal arc welding (CW-GMAW) vs. standard GMAW. Synchronized high-speed imaging with current and voltage samplings were used to characterize the arc dynamics for different cold wire mass feed rates. Subsequently, the droplet frequency and diameter were estimated, and the parameters for a globular-to-spray transition were assessed. The results suggest that the transition to spray occurs in CW-GMAW at a lower current than in the standard GMAW process. The reason for this difference appears to be linked to an enhanced magnetic pinch force, which is mainly responsible for metal transfer in higher welding current conditions.

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