Journal ArticleDOI
A theoretical study of a gas metal arc welding system
P. Zhu,M Rados,S W Simpson +2 more
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In this article, a theoretical model of a gas metal arc welding system was developed to make predictions of the anode temperature profile, welding arc length and arc current, for spray transfer.Abstract:
A theoretical model of a gas metal arc welding system has been developed to make predictions of the anode temperature profile, welding arc length and arc current. The model incorporates a one-dimensional thermal model of the moving consumable anode and a two-dimensional model for the arc plasma. The model makes possible the calculation of the relationship between the welding arc current, wire feed rate and the supply voltages, for various wire diameters and shielding gases. The predicted welding current for a given wire feed rate shows good agreement with our experimental observation for operation in the spray transfer mode, for steel wire of two different diameters, assuming a workpiece sheath voltage of 15 V.read more
Citations
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Journal ArticleDOI
Heat and mass transfer in gas metal arc welding. Part II: The metal
J. Hu,Hai-Lung Tsai +1 more
TL;DR: In this paper, a unified comprehensive model was developed to simulate the transport phenomena occurring during the gas metal arc welding process, where an interactive coupling between arc plasma; melting of the electrode; droplet formation, detachment, transfer, and impingement onto the workpiece; and weld pool dynamics all were considered.
Journal ArticleDOI
Modeling of the transport phenomena in GMAW using argon-helium mixtures. Part II - The metal
TL;DR: In this paper, the effects of shielding gas compositions on transport phenomena in the metal are reported which include the transient processes of electrode melting; droplet formation, detachment, transfer and impingement onto the workpiece; weld pool dynamics and weld bead formation.
Journal ArticleDOI
Three-Dimensional Modeling of the Plasma Arc in Arc Welding
Gu Xu,J. Hu,Hai-Lung Tsai +2 more
TL;DR: In this paper, a 3D model of the plasma arc was developed and the distributions of velocity, pressure, temperature, current density, and magnetic field of the arc were calculated by solving the conservation equations of mass, momentum, and energy.
Advanced Control Methods for Optimization of Arc Welding
TL;DR: A thorough derivation of the electromagnetic force is included in the thesis, and an arc length minimization algorithm is proposed for enhancing the ability to focus the arc, and also, to minimize the heat input into the workpiece.
Journal ArticleDOI
Metal Transfer and Arc Plasma in Gas Metal Arc Welding
J. Hu,Hai-Lung Tsai +1 more
TL;DR: In this paper, the transient complex heat transfer and fluid flow in molten metal and arc plasma during the gas metal arc welding process was analyzed and 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.
References
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Book
Numerical heat transfer and fluid flow
TL;DR: In this article, the authors focus on heat and mass transfer, fluid flow, chemical reaction, and other related processes that occur in engineering equipment, the natural environment, and living organisms.
Journal ArticleDOI
Moving Boundary Problems in Heat Flow and Diffusion
Journal ArticleDOI
Theory of free-burning arc columns including the influence of the cathode
J J Lowke,P Kovitya,H P Schmidt +2 more
TL;DR: In this paper, the current density at the cathode of a free-burning arc in argon with a tungsten cathode having a 60 degrees conical tip is determined to a good approximation by the arc column and cathode shape.
Journal ArticleDOI
A unified theory of free burning arcs, cathode sheaths and cathodes
Peiyuan Zhu,J J Lowke,R. Morrow +2 more
TL;DR: In this article, a theoretical method of predicting properties of free burning arcs and their cathodes is presented in a unified treatment, which combines a one-dimensional model of the non-equilibrium plasma sheath adjacent to the cathode and a twodimensional model for the arc column and the solid cathode.
Journal ArticleDOI
Temperature determinations in a free-burning arc. I. Experimental techniques and results in argon
G N Haddad,A J D Farmer +1 more
TL;DR: In this paper, spectroscopic techniques have been used to measure the temperature distribution in free-burning arcs in argon at 1 atm pressure, and the experiment provides evidence for departures from LTE in the arc, and demonstrates deficiencies in the theory describing continuum emission from high temperature plasmas.
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