Weld-metal nitrogen concentrations far in excess of Sieverts-law calculations during gas tungsten arc (GTA) welding of iron are investigated both experimentally and theoretically. A transient, three-dimensional mathematical model has been developed to calculate the residual nitrogen concentrations during GTA welding. This model combines calculations for the plasma phase with those for nitrogen absorption and for the transport of nitrogen by convection and diffusion in the weld metal and diffusion throughout the weldment. In addition, the model takes into account the roles of turbulence and the nitrogen desorption reaction in affecting the residual nitrogen concentration in the weldment. Autogeneous GTA welding experiments in pure iron have been performed and the resulting nitrogen concentrations compared with the modeling results. Both experimental and modeled nitrogen concentrations fall in a range between 2.7 and 4.7 times higher than Sieverts-law calculations at a temperature of 2000 K. Modeled nitrogen concentrations correlate well with the experimental results, both in magnitude and in the general trends, with changes in the travel speed and nitrogen addition to the shielding gas.
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