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Effects of evaporation-determined model of arc-cathode coupling on weld pool formation in GMAW process simulation

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Abstract

Currently used approaches for modeling the cathodic heat input in gas metal arc welding (GMAW) process simulation are usually based on very simplified approaches, either using a Rykalin-Rosenthal-distributed heat flux or a thermal conductivity approach, which do not reflect the deep physical processes involved. In this paper, a new approach for the calculation of the arc-cathode coupling in GMAW is presented, and the influence of the parameter variation on the formation of the weld pool is studied. The evaporation-determined model for arc-cathode coupling (EDACC) takes into account the recent findings on the plasma temperature in the GMAW arc, which is dominated by metal vapor, as well as the metal evaporation, which is readily ionized in the cathode region. It determines a relationship between the weld pool surface temperature and the heat flux as well as the current density distribution. As a result, the heat flux as well as the current density distribution is not axisymmetric. In this work, the model was coupled to a simplified weld pool simulation, and the influence of the model parameters like distribution of plasma temperature and welding velocity were investigated. Additionally, also the influence of the droplets on the weld pool surface temperature distribution and its effect on the arc-cathode attachment, as determined by the model, were studied.

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Funding

The presented investigations were carried out at the RWTH Aachen University within the framework of the Collaborative Research Centre SFB1120 “Precision Melt Engineering” (project no. 236616214) and were funded by the German Research Foundation (DFG). Simulations were performed with computing resources granted by the RWTH Aachen University under project rwth0398.

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  1. ISF – Welding and Joining Institute, RWTH Aachen University, Pontstr. 49, 52062, Aachen, Germany

    O. Mokrov, M. Simon, R. Sharma & U. Reisgen

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  1. O. Mokrov
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  2. M. Simon
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  3. R. Sharma
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  4. U. Reisgen
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Correspondence to M. Simon.

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Mokrov, O., Simon, M., Sharma, R. et al. Effects of evaporation-determined model of arc-cathode coupling on weld pool formation in GMAW process simulation . Weld World 64, 847–856 (2020). https://doi.org/10.1007/s40194-020-00878-3

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  • DOI: https://doi.org/10.1007/s40194-020-00878-3

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