The Effect of Groove Shape on Molten Metal Flow Behaviour in Gas Metal Arc Welding

TL;DR

This paper presents a simulation-based study on how groove shape influences molten metal flow in gas metal arc welding, combining numerical modeling with experimental validation to better understand melt-pool behaviour.

Contribution

The study introduces an enhanced physics-based 3D simulation model that captures the effects of groove shape on heat and fluid flow in GMAW, validated through experiments.

Findings

Groove shape significantly affects melt-pool heat and flow dynamics.

The computational model accurately predicts melt-pool behaviour across different groove geometries.

Simulation results align well with experimental observations.

Abstract

One of the challenges for development, qualification and optimisation of arc welding processes lies in characterising the complex melt-pool behaviour which exhibits highly non-linear responses to variations of process parameters. The present work presents a simulation-based approach to describe the melt-pool behaviour in root-pass gas metal arc welding (GMAW). Three-dimensional numerical simulations have been performed using an enhanced physics-based computational model to unravel the effect of groove shape on complex unsteady heat and fluid flow in GMAW. The influence of surface deformations on power-density distribution and the forces applied to the molten material was taken into account. Utilising this model, the complex heat and fluid flow in melt pools were visualised and described for different groove shapes. Additionally, experiments were performed to validate the numerical predictions and the robustness of the present computational model is demonstrated. The model can be used to explore physical effects of governing fluid flow and melt-pool stability during gas metal arc root welding.