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Development of a simulation model of the manual gas tungsten arc welding process and visualization of the welder’s skill

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Abstract

The quality of the weld is strongly dependent on the skill of the welder during the manual welding process. Recently, the number of skilled welders has decreased, which has highlighted the importance of improving the skill of the successors. However, it is difficult to quantitatively explain the skill of welders. In this study, a numerical model of the manual gas tungsten arc (GTA) welding process is developed, and the phenomena in the process and skill of welders are discussed. The properties of the heat source are calculated using the simulation model of the arc plasma and are employed in the weld pool model, which considers the feeding of the solid filler. The simulation model was applied to back-bead welding in the U-groove. The torch motion of the welders was observed by cameras and input into the model, and the weld shape of the simulation showed agreement with the experimental results. During the process, the weld pool spreads forward and fills the gap between the two base metals immediately after the filler is provided. The Marangoni effect is important for determining the flow on the weld pool surface. In addition, the influence of the torch motion on the occurrence of burn-through was investigated using the simulation model. The simulation results show that the balance of the welding speed, filler feeding speed, and frequency of wire feeding are important for the occurrence of burn-through.

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Authors and Affiliations

  1. Graduate School of Engineering, Osaka University, 2-1 Yamada-oka, Suita, Osaka, 565-0871, Japan

    Yosuke Ogino, Kota Imai & Satoru Asai

  2. Toshiba Energy Systems & Solutions Corporation, 2-4 Suehiro-cho, Tsurumi, Yokohama, Kanagawa, 230-0045, Japan

    Yoshihiro Tsujimura, Shinichiro Nakamura & Tsuyoshi Ogawa

Authors
  1. Yosuke Ogino
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  2. Kota Imai
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  3. Satoru Asai
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  4. Yoshihiro Tsujimura
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  5. Shinichiro Nakamura
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  6. Tsuyoshi Ogawa
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Correspondence to Yosuke Ogino.

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Recommended for publication by Commission XII - Arc Welding Processes and Production Systems

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Ogino, Y., Imai, K., Asai, S. et al. Development of a simulation model of the manual gas tungsten arc welding process and visualization of the welder’s skill. Weld World 66, 1381–1393 (2022). https://doi.org/10.1007/s40194-022-01307-3

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  • DOI: https://doi.org/10.1007/s40194-022-01307-3

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