The main objective of this study is to generate new understanding and improve computer methods for calculating the thermal cycles in the near weld region during gas metal arc (GMA) welding. Predicting the thermal cycle also provides an estimate of the depth of weld penetration, the geometry of the weld pool and the cooling rates. Both 2D and 3D finite-element models have been developed using the solution of heat-transfer equations. The accuracy of the predicted cooling times, weld penetrations and the lengths of the weld pools are compared with experimentally obtained values for bead-on-plate welds. A mechanical weld pool ejection rig developed in this study provided a quick and ready means of defining a full 3D weld-pool shape. A new numerical approach, `split heat source model' has been developed to model the arc heat. This gives good agreement with experimental data for a range of welding conditions.
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