Abstract
A three-dimensional coupled tungsten electrode–plasma arc–metal vapor– weld pool model was developed to investigate plasma arc and metal vapor characteristics, weld pool convection, and energy transfer in conduction plasma arc lap welding. The arc energy efficiency was also calculated. The numerical results showed that in conduction plasma arc lap welding, the constraint effects of the plasma arc by a small constricting nozzle, plasma gas, and electromagnetic force were strong, and no keyhole was formed inside the weld pool, so the heat flux on the weld pool surface was high as well as the weld pool temperature and mole fraction of Fe vapor above the weld pool surface. The high concentration of Fe vapor in the arc decreased the conduction energy from the plasma arc to the weld pool along with the arc energy efficiency. The calculated arc energy efficiency was only 50.2%. Without considering Fe vapor, the calculated weld pool had complete joint penetration. When considering Fe vapor, the calculated weld geometry agreed well with the experimental result.
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