Prediction of weld pool and reinforcement dimensions of GMA welds using a finite-element model

Abstract

Mathematical models of the gas metal arc (GMA) welding process may be used to study the influence of various welding parameters on weld dimensions, to assist in the development of welding procedures, and to aid in the generation of process control algorithms for automated applications. In this work, a three-dimensional (3-D), steady-state thermal model of the GMA welding process has been formulated for a moving coordinate framework and solved using the finite-element method. The model includes temperature-dependent material properties, a new finite-element formulation for the inclusion of latent heat of fusion, a Gaussian distribution of heat flux from the arc, plus the effects of mass convection into the weld pool from the melted filler wire. The influence of weld pool convection on the pool shape was approximated using anisotropically enhanced thermal conductivity for the liquid phase. Weld bead width and reinforcement height were predicted using a unique iterative technique developed for this purpose. In this paper, the numerical model is shown to be capable of predicting GMA weld dimensions for individual welds, including those with finger penetration. Also, good agreement is demonstrated between predicted weld dimensions and experimentally derived relations that describe the effects of process variables and their influence on average weld dimensions for bead-onplate GMA welds on steel plate.