The study of surface active element on weld pool development in A-TIG welding

Abstract

A 3D mathematical model was developed to simulate the weld pool development in a moving A-TIG weld pool with different oxygen and sulfur concentrations. It is shown that the surface active elements—oxygen and sulfur, which change the temperature coefficient of surface tension from a negative value to a positive one, can cause significant changes in fluid flow patterns and the weld penetration. When surface active element content increases, the weld penetration and depth/width ratio increase sharply and then remain nearly a constant. Positive temperature coefficient of surface tension dominates the fluid flow and the weld pool is narrow and deep. The further increasing surface active element content leads to an inappreciable difference in the weld pool size and shape when the oxygen content increases beyond 280 ppm and sulfur content beyond 125 ppm. Positive and negative temperature coefficients of surface tension co-exist in the weld pool when surface active element content is less than the critical value. The fluid flows in the weld pool change apparently with different surface active element. Depending upon the oxygen and sulfur concentrations, three, one or two vortexes that have different positions, strength and directions may be found in the weld pool. The vortexes with opposite direction caused by positive temperature coefficient of surface tension can efficiently transfer the thermal energy from the arc, creating a deep weld pool.