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Numerical simulation of arc and metal transfer behaviors in double-wire gas metal arc welding

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Abstract

The three-dimensional coupled arc-droplet models for traditional single-wire gas metal arc welding (SW-GMAW) and double-wire gas metal arc welding (DW-GMAW) were established. The mutual attraction of two arcs and the inclination of the droplets in DW-GMAW were analyzed numerically. The temperature, fluid flow velocity, and electromagnetic force distributions were compared between DW-GMAW and SW-GMAW. Compared with SW-GMAW, the temperature distribution on the workpiece surface was bimodal along x-axis and the peak temperature reduced in DW-GMAW. The high-temperature region in the filler metal was decreased dramatically. The fluid flow mode of the arc plasma in DW-GMAW was changed, and the peak velocity of the arc plasma decreased. Besides, the forces acted on the arc plasma were compared and the reason for the arc inclination was analyzed. Experimental data was used to validate the model’s predictions.

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Funding

This work is sponsored by the National Natural Science Foundation of China (Grant number 52005296), the Postgraduate Research and Practice Innovation Program of Jiangsu Province (Grant number SJCX22_1143), and the Graduate Innovation Program of China University of Mining and Technology (Grant number 2022WLJCRCZL280).

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Authors and Affiliations

  1. School of Materials Science and Physics, China University of Mining and Technology, Xuzhou, 221116, China

    Jie Xu, Yiming Ma & Lin Wang

  2. FAW Jiefang Automotive Company, Ltd. Qingdao Auto Factory, Qingdao, 266043, China

    Xu Lu

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  1. Jie Xu
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Correspondence to Lin Wang.

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Xu, J., Ma, Y., Wang, L. et al. Numerical simulation of arc and metal transfer behaviors in double-wire gas metal arc welding. Weld World 66, 2521–2531 (2022). https://doi.org/10.1007/s40194-022-01381-7

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