Numerical simulation of hump suppression in high-speed triple-wire GMAW
- 117 Downloads
Abstract
A numerical model of a three-dimensional transient weld pool was conducted to analyze the hump formation mechanism in high-speed single-wire gas metal arc welding (GMAW) and the hump suppression in triple-wire GMAW. The effect of heat convection, radiation, and vaporization on temperature field and the impact of arc pressure, surface tension, Lorentz force, buoyancy force, and droplet impinging force on the fluid flow field were considered during simulations. In good agreement with the experimental beads and images recorded by high-speed camera, the simulated results are shown: during the hump formation in single-wire GMAW, the liquid channel was formed, elongated, pinched, and solidified due to the strong backward molten metal flow and the normal surface tension. However, in the same line energy, humps were suppressed in triple-wire GMAW. The “pull-push” flow in the triple-wire GMAW weld pool could dramatically slow down the backward trend, which reduced the solidification rate. Consequently, the liquid channel disappears and the humps could not be formed any more.
Keywords
Triple-wire GMAW Hump suppression Numerical simulation High-speed weldingPreview
Unable to display preview. Download preview PDF.
References
- 1.Olsson R, Stemvers M, Staers I (1995) High-speed welding gives a competitive edge. Weld Rev Int 14(8):128–131Google Scholar
- 2.Lucas B (1997) FCAW, multiwire and gas selection: techniques to enhance MIG productivity. Weld Met Fabr 65(5):10–12Google Scholar
- 3.Ma X, Lin H, Hua X, Wu Y (2013) Full factorial design on triple-electrode high speed CO2 fillet welding on double sides. Trans Chin Weld Inst 5:025Google Scholar
- 4.Wu, D., Hua, X., Ye, D., Ma, X., & Li, F. (2016). Understanding of the weld pool convection in twin-wire GMAW process. The International Journal of Advanced Manufacturing Technology, 1-9. Doi: 10.1007/s00170-016-8775-1
- 5.Bradster BJ (1968) Effect of surface tension and metal flow on weld bead formation. Weld J 47(7):S314Google Scholar
- 6.Nguyen TC, Weckman DC, Johnson DA, Kerr HW (2005) The humping phenomenon during high speed gas metal arc welding. Sci Technol Weld Join 10(4):447–459CrossRefGoogle Scholar
- 7.Nguyen TC, Weckman DC, Johnson DA (2007) Predicting onset of high speed gas metal arc weld bead defects using dimensional analysis techniques. Sci Technol Weld Join 12(7):634–648CrossRefGoogle Scholar
- 8.Cho MH, Farson DF (2007) Understanding bead hump formation in gas metal arc welding using a numerical simulation. Metall Mater Trans B 38(2):305–319CrossRefGoogle Scholar
- 9.Chen MJ, Wu CS (2010) Numerical analysis of forming mechanism of hump bead in high speed GMAW. Weld World 54(9-10):R286–R291CrossRefGoogle Scholar
- 10.Chuansong CJW (2009) Numerical simulation of forming process of humping bead in high speed GMAW. Acta Metall Sin 45(9):1070–1076Google Scholar
- 11.Yokota MY, Shimizu MH, Nagaoka MS, Ito MK, Arita MH (2012) Development and application of the 3-electrode MAG high-speed horizontal fillet welding process. Weld World 56(1-2):43–47CrossRefGoogle Scholar
- 12.Lin H, Hua X, Ma X, Wang F, Wu Y, Oniki Y, Shi J (2008) Effect of welding speed and current on weld geometry in triple electrode high-speed CO2-shielded welding process. Hot Work Technol 23:029Google Scholar
- 13.Song Wu C, Tsao KC (1990) Modelling the three-dimensional fluid flow and heat transfer in a moving weld pool. Eng Comput 7(3):241–248CrossRefGoogle Scholar
- 14.Goldak J, Chakravarti A, Bibby M (1984) A new finite element model for welding heat sources. Metall Trans B 15(2):299–305CrossRefGoogle Scholar
- 15.Sahoo P, DebRoy T, McNallan MJ (1988) Surface tension of binary metal-surface active solute systems under conditions relevant to welding metallurgy. Metall Trans B 19(3):483–491CrossRefGoogle Scholar
- 16.Cho DW, Na SJ, Cho MH, Lee JS (2013) A study on V-groove GMAW for various welding positions. J Mater Process Technol 213(9):1640–1652CrossRefGoogle Scholar
- 17.Hu ZK, Wu CS (2008) Experimental investigation of forming process of humping bead in high speed MAG arc welding. Acta Metall Sin 44(12):1445–1449Google Scholar