Abstract
A thorough understanding of the physical mechanisms responsible for humping bead formation in high speed GMAW (gas metal arc welding) is essential to improve the welding productivity in today’s competitive manufacturing industries. Based on the experimental observing results, a mathematical model is developed to quantitatively analyze the forming mechanism of humping bead for high speed GMAW, considering both the momentum and heat content of the backward flowing molten metal in weld pools. One term related to the momentum of backward flowing molten metal is added to the equation of the weld pool surface deformation, and the heat content of overheated droplets is distributed within the layer covering the whole pool. The humping bead forming process and its dimension and 3-D geometry are numerically simulated under some welding conditions. It is found that the model can describe and characterize the humping formation in high speed GMAW quantitatively.
Similar content being viewed by others
References
Nguyen T.C., Weckman D.C., Johnson D.A., Keer H.W.: High speed fusion weld bead defects, Science and Technology of Welding and Joining, 2006, vol. 11, no. 6, pp. 618–633.
Nguyen T.C., Weckman D.C., Johnson DA, Keer H.W.: The humping phenomenon during high speed gas metal arc welding, Science and Technology of Welding and Joining, 2005, vol. 10, no. 4, pp. 447–459.
Mendez P.F., Eager T.W.: Penetration and defect formation in high-current arc welding, Welding Journal, 2003, vol. 82, no. 10, pp. 296s–306s.
Kumar A., DebRoy T: Toward a unified model to prevent humping defects in gas tungsten arc welding, Welding Journal, 2006, vol. 85, no. 12, pp. 292s–304s.
Bradstreet B.J.: Effect of surface tension and metal flow on weld bead formation, Welding Journal, 1968, vol. 47, no. 7, pp. 314s–322s.
Gratzke U., Kapadia P.D., Dowden J., Kroos J., Simon G.: Theoretical approach to the humping phenomenon in welding processes, Journal of Physics D: Applied Physics, 1992, vol. 25, no. 11, pp. 1640–1647.
Cho M.H.: Numerical simulation of arc welding process and its application, PhD thesis, Ohio State University, Columbus, Ohio, USA, 2006.
Cho M.H, Farson M.F.: Understanding bead hump formation in gas metal arc welding using a numerical simulation, Metallurgical and Materials Transactions B, 2007, vol. 38, no. 2, pp. 305–319.
Zhao P.C., Wu C.S., Zhang Y.M.: Numerical simulation of the dynamic characteristics of weld pool geometry with step-changes of welding parameters, Modelling and Simulation in Materials Science and Engineering, 2004, vol. 12, pp. 765–780.
Ushio M., Wu C.S.: Mathematical modelling of 3-D heat and fluid flow in a moving GMA weld pool, Metallurgical and Materials Transactions B, 1997, vol. 28, no. 6, pp. 509–516.
Hu Z.K., Wu C.S.: Experimental investigation of forming process of humping bead in high speed MAG arc welding, Acta Metallurgica Sinica, 2008, vol. 44, no. 12, pp. 1445–1449.
Wu C.S., Chen J., Zhang Y.M.: Numerical analysis of both front- and back-side deformation of fully-penetrated GTAW weld pool surfaces, Computational Materials Science, 2007, vol. 39, no. 4, pp. 635–642.
Author information
Authors and Affiliations
Rights and permissions
About this article
Cite this article
Chen, J., Wu, CS. Numerical Analysis of Forming Mechanism of Hump Bead in High Speed GMAW. Weld World 54, R286–R291 (2010). https://doi.org/10.1007/BF03266741
Published:
Issue Date:
DOI: https://doi.org/10.1007/BF03266741