Numerical analysis of arc physics and energy transfer under circumferential gas constraint effect

Abstract

Energy dispersion and easy instability associated with arcs, the traditional metal processing heat source, restrict its development and application in the modern high-precision welding and additive manufacturing. This work aims to study the characteristics of a novel arc under circumferential gas constraint effect which can improve the arc stability and processing accuracy. A magnetohydrodynamics model was established to calculate the arc physics and heat transfer, considering the electron emission characteristics of tungsten and the effect of metal vapor. It indicates that the annular flexible constrained gas flow can significantly increase the physical characteristics such as arc temperature, plasma flow velocity and current density compared with traditional free arc which is named GTA. The arc heat generation increasement of the novel arc makes the heat transfer from arc to base metal higher than that of GTA. The additional annular gas flow inhibits the diffusion of metal vapor, stabilizing the arc and protecting the tungsten electrode from contamination. However, as the arc length decreases, eddy of arc plasma flow appears inside the arc, which can cause metal vapor to contaminate the tungsten. It's found that this novel gas flow constrained arc needs to be applied with a small current when welding with small arc length to avoid the eddy. Finally, the accuracy of the calculation model is verified by experimental detection of arc temperature.