Abstract
Gas metal arc welding (GMAW) processes are characterized by a high number of simultaneously running physical processes. The process capability is mainly determined by the properties of a metal vapour influenced arc and the material transfer. In recent years, experimental as well as numerical methods are being used increasingly in order to understand the complex interactions between the arc and material transfer. In this paper, we discuss the influence of metal vapour on GMAW processes in spray as well as pulsed material transfer mode. With respect to the high complexity of the process, experimental and numerical methods are combined in a targeted manner in order to obtain a high level of expressive capability with moderate numerical and experimental effort. The results illustrate the high influence of the changing vaporization rate not only on the arc properties but on the arc attachment at the filler wire. It could be shown, that in many cases the metal vapour concentration in the arc region has a greater influence on the arc properties and the material transfer than different shielding gas components like oxygen, hydrogen or helium.
Similar content being viewed by others
References
Norish J (2006) Advanced welding processes. Woodhead Publishing. https://www.elsevier.com/books/advanced-welding-processes/norrish/978-1-84569-130-1
Murphy AB (2010) The effects of metal vapour in arc welding. J Phys D Appl Phys 43:434001
Murphy AB (2016) A perspective on arc welding research: the importance of the arc, unresolved questions and future directions. Plasma Chem Plasma Process 35(3):471–489
Goecke SF (2004) Auswirkungen von Aktivgaszumischungen im vpm-Bereich zu Argon auf das MIG-Impulsschweissen von Aluminium. Dissertation TU Berlin
Zielinska S, Musiol K, Dzierzega K, Pellerin S, Valensi F, de Izarra Ch, Briand F (2007) Investigations of GMAW plasma by optical emission spectroscopy. Plasma Sources Sci Technol 16:832
Rouffet ME, Wendt M, Goett G, Kozakov R, Schöpp H, Weltmann KD, Uhrlandt D (2010) Spectroscopic investigation of the high-current phase of a pulsed GMAW process. J Phys D Appl Phys 43:434003
Tsujimura Y and Tanaka M (2013) Plasma diagnostics in gas–metal arcs during welding. In: IIW conference Denver 2012, SG 212-meeting, IIW Doc. 212-1237-12
Kozakov R, Gött G, Schöpp H, Uhrlandt D, Schnick M, Hässler M, Füssel U, Rose S (2013) Spatial structure of the arc in the pulsed GMAW process. J Phys D Appl Phys 46:224001
Haidar J, Lowke JJ (1996) Predictions of metal droplet formation in arc welding. J Phys D Appl Phys 29(12):2951
Fan HG, Kovacevic R (2004) A unified model of transport phenomena in gas–metal arc welding including electrode, arc plasma and molten pool. J Phys D Appl Phys 37:2531
Xu G, Hu J, Tsai HL (2009) Three-dimensional modeling of arc plasma and metal transfer in gas metal arc welding. Int J Heat Mass Transf 52:1709–1724
Schnick M, Füssel U, Hertel M, Spille-Kohoff A, Murphy AB (2010) Metal vapour causes a central minimum in arc temperature in gas–metal arc welding through increased radiative emission. J Phys D Appl Phys 43:022001
Schnick M, Füssel U, Hertel M, Haessler M, Spille-Kohoff A, Murphy AB (2010) Modelling of gas–metal arc welding taking into account metal vapour. J Phys D Appl Phys 43:434008
Pfender E (1980) Energy transport in thermal Plasmas. Pure Appl Chem 52:1773–1800
Heberlein J, Mentel J, Pfender E (2010) The anode region of electric arcs: a survey. J Phys D Appl Phys 43(2):023001
Krivtsun I, Demchenko V, Lesnoi A, Krikent I, Poritsky P, Mokrov O, Reisgen U, Zabirov A, Pavlyk V (2010) Modelling of electromagnetic processes in system’welding arc—evaporating anode’: I. Model of anode region. Sci Technol Weld Join 15:457–462
Krivtsun I, Demchenko V, Lesnoi A, Krikent I, Poritsky P, Mokrov O, Reisgen U, Zabirov A, Pavlyk V (2010) Modelling of electromagnetic processes in system ‘welding arc—evaporating anode’: II. Model of arc column and anode metal Sci. Technol Weld Join 15:463–467
Boselli M, Colombo V, Ghedini E, Gherardi M, Sanibondi P (2012) Two-dimensional time-dependent modelling of fume formation in a pulsed gas metal arc welding process. J Phys D Appl Phys 46:224006
Hertel M, Spille-Kohoff A, Füssel U, Schnick M (2013) Numerical simulation of droplet detachment in pulsed gas–metal arc welding including the influence of metal vapour. J Phys D Appl Phys 46:224003
Ogino Y, Hirata Y (2015) Numerical simulation of metal transfer in argon gas-shielded GMAW. Weld World 59(4):465–473
Hirt CW, Nichols BD (1981) Volume of fluid (VOF) method for the dynamics of free boundaries. J Comput Phys 39:201–225
Ogino Y, Yoshinori Hirata, Murphy AB (2016) Numerical simulation of GMAW process using Ar and an Ar-CO2 gas mixture. Weld World 60(2):345–353
Rose S (2013) Einfluss des Werkstoffübergangs auf das dynamische Prozessverhalten beim Metallschutz-gasschweißen. Dissertation TU Dresden
Hertel M, Niese J, Rose S, Häßler M, Füssel U, Uhrlandt D (2015) Experimental und numerical investigations into the influence of the shielding gas composition on the GMA spray arc process. Weld Cut 14(5):234–441
Hertel M, Rose S, Füllel U (2016) Numerical simulation of arc and droplet transfer in pulsed GMAW of mild steel in argon. Weld World 60(5):1055–1061
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Hertel, M., Trautmann, M., Jäckel, S. et al. The Role of Metal Vapour in Gas Metal Arc Welding and Methods of Combined Experimental and Numerical Process Analysis. Plasma Chem Plasma Process 37, 531–547 (2017). https://doi.org/10.1007/s11090-017-9790-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11090-017-9790-1