Abstract
The process of the mechanised plasma-arc butt-welding of thin-gauge mild-steel sheets has been studied, both theoretically and experimentally. The transient temperature distribution has been computed using an analytical model due to Rosenthal. The results have then been compared with those generated by finite-element analysis using the commercial package PAFEC. The two sets of results were found to be in reasonably good agreement; moreover, the theoretical values were found to correlate fairly well with the results of experiments performed on a Messer Griesheim Uniwig G-200P plasma-arc welding machine. The extent of the heat-affected zone (HAZ) in the butt-welded specimens has been computed by analysing the temperature history at points lying transverse to the weldment: the theoretical values match fairly closely with those obtained from the welding experiments. The efficiency of the plasma-arc welding process has been estimated to be around 32% to 35%.
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