A self-consistent three-dimensional model of the arc, electrode and weld pool in gas–metal arc welding

The development of a three-dimensional computational model of gas–metal arc welding is described. The wire electrode, arc plasma and weld pool are included in the computational domain self-consistently. The model takes into account the motion of the electrode, flow in the weld pool, deformation of the weld-pool surface and the influence of metal droplet transfer. Results are presented for welding of an aluminium alloy. The current density distribution at the interface between the arc and the weld pool is strongly dependent on the surface profile of the weld pool. This in turn affects the temperature distribution in the weld pool. The momentum transferred by the droplet affects the direction of flow in the weld pool, and together with the energy transfer, increases the weld-pool depth. The results demonstrate the importance of including the arc plasma in the computational domain. Fair agreement is found between a measured weld profile and the predictions of the model. Inclusion of the influence of metal vapour in the model is expected to improve the agreement.