Weld process model for simulating metal active gas welding

  • Dénes KollárEmail author
  • Balázs Kövesdi
  • László Gergely Vigh
  • Sándor Horváth
Open Access


Generally, optimum welding variables and conditions of manufacturing are currently mainly determined by experiments for standardized production. Virtual manufacturing and virtual testing of weldments using finite element method provide a sustainable solution for advanced applications. The aim of the current research work is to develop a weld process model, using a three-dimensional heat transfer model, to ensure general applicability for typical joints of stator segments of wind turbines as a final application. A systematic experimental research program, containing temperature measurements during welding, macrographs, and deformation measurements, is carried out on small-scale test specimens using different welding variables. In addition, a numerical study using uncoupled transient thermomechanical analysis is performed. The weld process model uses Goldak’s double ellipsoidal heat source model for a metal active gas welding power source. It describes the correspondence between heat source parameters and net heat input for two types of electrodes. The model is validated via cross-sectional areas of fusion zones and deformations based on experiments. The relationship between current and voltage is determined based on large number of experimental data; thus, selecting a wire type, travel speed, and voltage directly defines the heat source parameters of the weld process model.


Welding simulation Heat source model Validation Metal active gas welding Numerical simulation Weld process model 


Funding information

Open access funding provided by Budapest University of Technology and Economics (BME). The presented research program received funding from Hungarian R&D project under grant agreement no. GINOP-2.1.1-15-2016-008854. The second author of the paper was supported by the ÚNKP-18-4 New National Excellence Program of the Ministry of Human Capacities and by the János Bolyai Research Scholarship of the Hungarian Academy of Sciences.


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Copyright information

© The Author(s) 2019

Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (, which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.

Authors and Affiliations

  • Dénes Kollár
    • 1
    Email author
  • Balázs Kövesdi
    • 1
  • László Gergely Vigh
    • 1
  • Sándor Horváth
    • 2
  1. 1.Department of Structural EngineeringBudapest University of Technology and EconomicsBudapestHungary
  2. 2.Lakics Machine Manufacturing Ltd.KaposvárHungary

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