Predictions of weld pool profiles using plasma physics
TL;DR: In this paper, a review of recent papers which have led to the capability of the prediction of weld depths for gas tungsten arc welding, for any given arc current, electrode shape or separation and welding gas, is given.
Abstract: This paper gives a review of recent papers which have led to the capability of the prediction of weld depths for gas tungsten arc welding, for any given arc current, electrode shape or separation and welding gas. The methodology is given for deriving plasma composition as a function of temperature and pressure from basic atomic and molecular properties. Transport coefficients of density, specific heat, enthalpy, electrical conductivity, thermal conductivity, viscosity and radiation emission coefficients can then be derived as a function of temperature. The conservation equations of fluid dynamics are then used to derive weld profiles for stainless steel for welding gases such as argon, helium, carbon dioxide and a 10% mixture of hydrogen in argon. The markedly different weld depths which are obtained are related to basic material functions such as specific heat, electrical and thermal conductivity. The temperature dependence of the surface tension coefficient has a marked effect on weld depth and profiles because it can influence the direction of circulatory flow in the weld pool. Electric arcs in helium and carbon dioxide are more constricted than arcs in argon and as a consequence the magnetic pinch pressure of the arc, transmitted to the weld pool, can force strong downward flows in the weld pool and thus lead to a deep weld. It is found that because of the interactions of the arc and the weld pool through effects such as viscous drag forces of the plasma on the weld pool, it is necessary to treat the arc, the electrode and the weld pool in a unified system.
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TL;DR: In this article, the effect of metal vapour on the distributions of temperature, current density and heat flux in arcs is examined in terms of these thermophysical properties, and different approaches to treat diffusion of metal vapor in plasmas, and the production of vapour from molten metal, are compared.
Abstract: Metal vapour is formed in arc welding processes by the evaporation of molten metal in the weld pool, and in the case of gas–metal arc welding, in the wire electrode and droplets. The presence of metal vapour can have a major influence on the properties of the arc and the size and shape of the weld pool. Previous experimental and computational works on the production and transport of metal vapour in welding arcs, in particular those relevant to gas–metal arc welding and gas–tungsten arc welding, are reviewed. The influence of metal vapour on the thermodynamic, transport and radiative properties of plasmas is discussed. The effect of metal vapour on the distributions of temperature, current density and heat flux in arcs is examined in terms of these thermophysical properties. Different approaches to treating diffusion of metal vapour in plasmas, and the production of vapour from molten metal, are compared. The production of welding fume by the nucleation and subsequent condensation of metal vapour is considered. Recommendations are presented about subjects requiring further investigation, and the requirements for accurate computational modelling of welding arcs.
230 citations
TL;DR: In this article, the influence of thermophysical properties on the parameters of tungsten-inert-gas (TIG) welding arcs, particularly those that affect the weld pool, is investigated using a two-dimensional model in which the arc, anode and cathode are included self-consistently.
Abstract: The methods used to model thermal plasmas, including treatments of diffusion in arcs in gas mixtures, are reviewed. The influence of thermophysical properties on the parameters of tungsten–inert-gas (TIG) welding arcs, particularly those that affect the weld pool, is investigated using a two-dimensional model in which the arc, anode and cathode are included self-consistently. The effect of changing each of six thermophysical properties on the characteristics of an argon TIG arc is assessed. The influence of the product of specific heat and mass density is found to be particularly important in determining the arc constriction. By examining the influence of the different properties on the heat flux density, current density and shear stress at the anode, it is concluded that the weld pool depth can be increased by using shielding gases with high specific heat, thermal conductivity and viscosity. The effect of metal vapour on the arc and weld pool properties is assessed. The most important effect of the metal vapour is found to be the increased electrical conductivity at low temperatures, which leads to lower heat flux density and current density at the weld pool, implying a shallower weld pool.
160 citations
TL;DR: Inconel 718 (2mm thick) was welded using argon and helium gas shielded tungsten arc welding process with a filler metal and the cooling rates calculated as mentioned in this paper.
121 citations
TL;DR: In this article, the influence of adding helium, hydrogen and nitrogen to the argon shielding gas is investigated and it is found that adding any of the gases increases the heat flow to and the current density at the anode.
Abstract: Tungsten?inert-gas welding arcs are modelled using a two-dimensional axisymmetric computational code. Both electrodes (the tungsten cathode and the metal anode workpiece) and the arc plasma are included self-consistently in the computational domain. The influence of adding helium, hydrogen and nitrogen to the argon shielding gas is investigated. It is found that addition of any of the gases increases the heat flow to and the current density at the anode. The shear stress and the arc pressure at the anode surface are increased by adding hydrogen or nitrogen or up to about 50?mol% helium, but decrease when more helium is added. It is predicted that the effect of adding any of the gases is to increase the depth of the weld pool, in agreement with the experimental evidence. The results are explained by referring to the thermodynamic and transport properties of the gas mixtures.
114 citations
TL;DR: In this article, a computational model of the argon arc plasma in gas-metal arc welding (GMAW) that includes the influence of metal vapour from the electrode is presented, and the occurrence of a central minimum in the radial distributions of temperature and current density is demonstrated.
Abstract: A computational model of the argon arc plasma in gas‐metal arc welding (GMAW) that includes the influence of metal vapour from the electrode is presented. The occurrence of a central minimum in the radial distributions of temperature and current density is demonstrated. This is in agreement with some recent measurements of arc temperatures in GMAW, but contradicts other measurements and also the predictions of previous models, which do not take metal vapour into account. It is shown that the central minimum is a consequence of the strong radiative emission from the metal vapour. Other effects of the metal vapour, such as the flux of relatively cold vapour from the electrode and the increased electrical conductivity, are found to be less significant. The different effects of metal vapour in gas‐tungsten arc welding and GMAW are explained.
110 citations
References
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Book•
01 Jan 1980
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.
Abstract: This book focuses on heat and mass transfer, fluid flow, chemical reaction, and other related processes that occur in engineering equipment, the natural environment, and living organisms. Using simple algebra and elementary calculus, the author develops numerical methods for predicting these processes mainly based on physical considerations. Through this approach, readers will develop a deeper understanding of the underlying physical aspects of heat transfer and fluid flow as well as improve their ability to analyze and interpret computed results.
21,858 citations
1,130 citations
Book•
01 Jan 1984
TL;DR: In this paper, the authors describe electric arc welding, high energy density welding, and future developments of welding processes, and discuss the benefits of better understanding of the physics of welding.
Abstract: Greater understanding of the physics of welding is leading to improved application and control of welding processes. Further gains in welding productivity could follow. Electric arc welding, high energy density welding and future developments are described
656 citations
TL;DR: In this paper, the viscosity, thermal conductivity, and electrical conductivity of argon, nitrogen, and oxygen plasmas, and mixtures of gas mixtures, are presented.
Abstract: Calculated values of the viscosity, thermal conductivity, and electrical conductivity of argon, nitrogen, and oxygen plasmas, and mixtures of argon anti nitrogen and of argon anti oxygen, are presented. In addition, combined ordinary, pressure, and thermal diffusion coefficients are given for the gas mixtures. These three combined diffusion coefficients fully describe di fusion of the two gases, irrespective of their degree of dissociation or ionizati on. The calculations, which assume local thermodynamic equilibrium, are performed! for atmospheric-pressure plasmas in the temperature range /torn 300 to 30,000 K. A number of the collision integrals used in calculating the transport coefficients are significantly more accurate than values used in previous theoretical studies, resulting in more reliable values of the transport coefficients. The results are compared with those of published theoretical and experimental studies.
450 citations