Multi-physics coupling simulation of GMAW arc and droplet behaviors based on CFD

IF 2.4 4区材料科学 Q2 METALLURGY & METALLURGICAL ENGINEERING

Welding in the World Pub Date : 2024-07-17 DOI:10.1007/s40194-024-01806-5

Zhang Yujiao, Li Yinghao, Niu Sizhe, Wang Hongtao, Zong Ran

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Abstract

A three-dimensional transient model of gas metal arc welding (GMAW) process including the arc plasma and droplet transfer was established to investigate the complex coupling mechanism of mass transfer, heat transfer, electromagnetism, and hydrodynamics. The arc shape, current density, temperature field, electromagnetic force, arc pressure and droplet behavior were analyzed. The results showed that the iron vapor generated on the droplet surface and diffused in the arc, which changed the plasma thermal-pressure distribution. The upward surface tension maintained the forming droplet at the wire tip. The electromagnetic force promoted necking, resulting in a decrease in surface tension. Gravity and plasma drag force accelerated the droplet. The behaviors of the inner arc layer varied periodically with the droplet transfer, while the arc periphery remained stable. Droplet transfer was the result of periodic changes in the resultant of all external forces over time, which also led to periodic changes in arc behavior. This study laid the foundation for further research on the influence of arc and droplet behaviors on the weld pool.

Graphical Abstract

Abstract Image

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基于 CFD 的 GMAW 电弧和液滴行为多物理场耦合模拟

建立了包括电弧等离子体和熔滴传递在内的气体金属电弧焊（GMAW）过程三维瞬态模型，以研究传质、传热、电磁和流体力学的复杂耦合机制。分析了电弧形状、电流密度、温度场、电磁力、电弧压力和液滴行为。结果表明，铁蒸汽在液滴表面生成并在电弧中扩散，改变了等离子体的热压分布。向上的表面张力将成形液滴保持在焊丝尖端。电磁力促进了缩颈，导致表面张力下降。重力和等离子体阻力加速了液滴。电弧内层的行为随液滴转移而周期性变化，而电弧外围则保持稳定。液滴转移是所有外力的结果随时间周期性变化的结果，这也导致了电弧行为的周期性变化。这项研究为进一步研究电弧和熔滴行为对焊接熔池的影响奠定了基础。

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来源期刊

Welding in the World METALLURGY & METALLURGICAL ENGINEERING-

CiteScore

4.20

自引率

14.30%

发文量

181

审稿时长

6-12 weeks

期刊介绍： The journal Welding in the World publishes authoritative papers on every aspect of materials joining, including welding, brazing, soldering, cutting, thermal spraying and allied joining and fabrication techniques.