Numerical evaluation of interwire angle influence on molten pool fluid dynamics and weld defects in tandem NG-GMAW of 5083 aluminum alloy

Abstract

The impact of interwire angle on the fluid dynamics and weld defects in tandem NG-GMAW of 5083 AlMg alloy was investigated through experimental and simulation methods. The rotating coordinate system was employed to model the inclined arc and arc interaction, while a pulsed Gaussian distribution arc model was adopted to consider factors such as arc heat, arc pressure and drag force. Experimental results demonstrate that different interwire angles lead to different weld formation and varying levels of porosity and pore distribution. A sound weld bead with no formation defect and low porosity was achieved when the interwire angle was set at 10°. Simulation results illustrate the relationship between weld formation, bubble escape and molten pool fluid dynamics under diverse interwire angles. As the interwire angle increases, the weld surface becomes concave. At the interwire angle of 0°, the weld bead surface appears leveled and porosity tends to occur near the sidewalls due to roundabout flows in that region. At an interwire angle of 14°, roundabout flows converge at the central longitudinal section, resulting in significant porosity in this area. However, when the interwire angle is set at 10°, backward flows driven by two arcs suppresses roundabout flow throughout the entire molten pool, leading to a lower percentage of porosity area.