Analysis of Molten Pool Characteristics on Hybrid GMAW Process

Abstract

This paper presents a complementary experimental and numerical investigation of thermal and welds bead characteristics of GMAW for flat wire electrode (FE-GMAW). The welding parameters for the FE-GMAW process are Welding Current (I), Stick out Distance (SD), Welding Speed (WS), Gas flow rate (Q), Welding feed rate (f) and Dimensions of the Flat Electrode (DFE) which have the most effect on the weld bead performance as consider. To analyses the effect of weld bead performance a FEA simulation is carried out using Ansys apdl for transient thermal analysis. The analysis with different combinations of the parameters such as voltage, current, and efficiency. From the analysis, temperature distribution is evaluated for the weld bead and the results of numerical are compared with the experimental values. This paper also deals with thermal and droplet characteristics in GMAW for flat wire electrode (FE-GMAW). By considering the above mentioned welding parameters the characteristics of the weld samples are analyzed, and also investigate droplet and thermal characteristics such as droplet formation, detachment, transfer and impingement and their temperature difference during the FE-GMAW process. Then, Computational Fluid Dynamics (CFD) package, CFX which employ the volume of fluid (VOF) method is to be carried out to understand the droplet and thermal characteristics and predictions were compared with experimental results.