Study of weld formation in swing arc narrow gap vertical GMA welding by numerical modeling and experiment

摘要

A three-dimensional unified model is proposed to simulate the weld pool dynamic behavior in swing arc narrow gap vertical GMA welding with allowing for swing feature of arc heat source and joint configuration. Both the moving direction of arc and its inclination are considered by transformation of coordinate system. The model can simulate the weld pool sagging process reasonably. Based on the calculated and experimental results, the mechanism of weld formation in swing arc vertical-up welding is studied. The weld pool size and the peak temperature of liquid metal are reduced largely in the case of swing arc, which leads to the faster solidification of weld pool and is the major factor responsible for suppression of weld pool sagging. Meanwhile, upward component of arc force and the enhanced support force from solidified metal bulge benefits the weakness of downward flow of liquid metal. With increasing the swing frequency, weld cross section geometry tends to be symmetrical and weld bead surface becomes smoother. When the swing frequency is higher than 0.6 Hz, the satisfied weld formation can be obtained.