Numerical investigation of surface ripple formation in pulsed direct current gas tungsten arc welding

IF 5 2区工程技术 Q1 ENGINEERING, MECHANICAL

International Journal of Thermal Sciences Pub Date : 2025-10-18 DOI:10.1016/j.ijthermalsci.2025.110400

C.Y. Kuo, D.J. Wang, P.H. Li, S.X. Lu, P.S. Wei, W.L. Cheng

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Abstract

This study investigates the dynamic interactions between the arc and molten pool during pulsed direct current electrode positive (DCEP) gas tungsten arc welding (GTAW), with a focus on post-solidification surface roughness. A transient two-dimensional multiphysics model is developed to simulate fluid flow, heat transfer, and solute transport under a pulsed heat source. The model incorporates thermocapillary, solute-capillary, and electrocapillary forces, along with Lorentz forces induced by the transient electromagnetic field. Using COMSOL Multiphysics 6.0, the evolution of velocity, pressure, temperature, concentration, and electromagnetic distributions within the molten pool is analyzed. Results reveal that thermocapillary force dominates surface roughness formation, with solute-capillary effects contributing locally, while electrocapillary influence is negligible. Periodic variations in current induce corresponding surface flows and ripple structures, particularly at the rear of the molten pool. The predictions align well with both numerical simulations and experimental observations. The modeling framework and insights presented here are applicable to process control and quality optimization in arc welding, laser welding, and additive manufacturing.

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脉冲直流钨气弧焊中表面纹波形成的数值研究

研究了脉冲直流电极正极（DCEP）气体钨极电弧焊（GTAW）过程中电弧与熔池之间的动态相互作用，重点研究了凝固后表面粗糙度。建立了一个二维瞬态多物理场模型来模拟脉冲热源下的流体流动、传热和溶质输运。该模型结合了热毛细力、溶质毛细力和电毛细力，以及瞬变电磁场诱导的洛伦兹力。利用COMSOL Multiphysics 6.0软件对熔池内的速度、压力、温度、浓度和电磁分布进行了分析。结果表明，热毛细力主导了表面粗糙度的形成，溶质毛细效应在局部起作用，而电毛细的影响可以忽略不计。电流的周期性变化引起相应的表面流动和波纹结构，特别是在熔池的后部。这些预测与数值模拟和实验观测结果都很吻合。本文提出的建模框架和见解适用于弧焊、激光焊接和增材制造的过程控制和质量优化。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

International Journal of Thermal Sciences 工程技术-工程：机械

CiteScore

8.10

自引率

11.10%

发文量

531

审稿时长

55 days

期刊介绍： The International Journal of Thermal Sciences is a journal devoted to the publication of fundamental studies on the physics of transfer processes in general, with an emphasis on thermal aspects and also applied research on various processes, energy systems and the environment. Articles are published in English and French, and are subject to peer review. The fundamental subjects considered within the scope of the journal are: * Heat and relevant mass transfer at all scales (nano, micro and macro) and in all types of material (heterogeneous, composites, biological,...) and fluid flow * Forced, natural or mixed convection in reactive or non-reactive media * Single or multi–phase fluid flow with or without phase change * Near–and far–field radiative heat transfer * Combined modes of heat transfer in complex systems (for example, plasmas, biological, geological,...) * Multiscale modelling The applied research topics include: * Heat exchangers, heat pipes, cooling processes * Transport phenomena taking place in industrial processes (chemical, food and agricultural, metallurgical, space and aeronautical, automobile industries) * Nano–and micro–technology for energy, space, biosystems and devices * Heat transport analysis in advanced systems * Impact of energy–related processes on environment, and emerging energy systems The study of thermophysical properties of materials and fluids, thermal measurement techniques, inverse methods, and the developments of experimental methods are within the scope of the International Journal of Thermal Sciences which also covers the modelling, and numerical methods applied to thermal transfer.