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A switching arc in a model circuit breaker is studied by means of CFD simulations and optical emission spectroscopy. The arc is initiated between tungsten–copper electrodes in a carbon dioxide atmosphere and is led through PTFE (polytetrafluorethylene) nozzles. Radiation emitted by the arc plasma is absorbed by the surface of the nozzles leading to ablation of the wall material. The CFD simulations are based on a model of the arcing zone including a consistent treatment of the radiation transport and wall ablation. Carbon ion line radiation is analysed in the experiment using an optical path in the heating channel between the nozzles. Temperature profiles obtained from spectroscopy and simulations are compared. The pressure value in the arc is estimated based on the line width-intensity dependence. The obtained values correspond to the measured pressure outside the arc. Coincidence in temperature for the peak current and discrepancy on the falling edge are found and discussed.

This work presents modelling results concerning a tungsten inert gas (TIG) welding arc. The model provides a consistent description of the free burning arc, the arc attachment and the electrodes. Thermal and chemical nonequilibrium is considered in the whole arc area, and a detailed model of the cathode space-charge sheath is included. The mechanisms in the cathode pre-sheath are treated in the framework of a non-equilibrium approach which is based on a twofluid description of electrons and heavy particles and a simplified plasma chemistry of argon. A consistent determination of the electrode fall voltages and temperature distributions is achieved. The model is applied to arcs in pure argon at currents up to 250 A, whereby welding of a workpiece made of mild steel with a fixed burner is considered. Arc voltages in the range from 12 to 17 V are obtained at 50 at 250 A, respectively. The space-charge sheath voltage is found to be about 7 V and almost independent of the current. The corresponding temperatures of the cathode tip are in the range from 3,000 K to about 3,800 K. The results obtained are in a good agreement with measurements.

In this paper we introduce an experimental technique that allows for high-speed, three-dimensional determination of electron density and temperature in axially symmetric free-burning arcs. Optical filters with narrow spectral bands of 487.5–488.5 nm and 689–699 nm are utilized to gain two-dimensional spectral information of a free-burning argon tungsten inert gas arc. A setup of mirrors allows one to image identical arc sections of the two spectral bands onto a single camera chip. Two-different Abel inversion algorithms have been developed to reconstruct the original radial distribution of emission coefficients detected with each spectral window and to confirm the results. With the assumption of local thermodynamic equilibrium we calculate emission coefficients as a function of temperature by application of the Saha equation, the ideal gas law, the quasineutral gas condition and the NIST compilation of spectral lines. Ratios of calculated emission coefficients are compared with measured ones yielding local plasma temperatures. In the case of axial symmetry the three-dimensional plasma temperature distributions have been determined at dc currents of 100, 125, 150 and 200 A yielding temperatures up to 20000 K in the hot cathode region. These measurements have been validated by four different techniques utilizing a high-resolution spectrometer at different positions in the plasma. Plasma temperatures show good agreement throughout the different methods. Additionally spatially resolved transient plasma temperatures have been measured of a dc pulsed process employing a high-speed frame rate of 33000 frames per second showing the modulation of the arc isothermals with time and providing information about the sensitivity of the experimental approach.

Temperature determination of liquid metals is difficult but a necessary tool for improving materials and processes such as arc welding in the metal-working industry. A method to determine the surface temperature of the weld pool is described. A TIG welding process and absolute calibrated optical emission spectroscopy are used. This method is combined with high-speed photography. 2D temperature profiles are obtained. The emissivity of the radiating surface has an important influence on the temperature determination. A temperature dependent emissivity for liquid steel is given for the spectral region between 650 and 850 nm.

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The controlled metal transfer process (CMT) is a variation of the gas metal arc welding (GMAW) process which periodically varies wire feeding speed. Using a short-arc burning phase to melt the wire tip before the short circuit, heat input to the workpiece is reduced. Using a steel wire and a steel workpiece, iron vapour is produced in the arc, its maximum concentration lying centrally. The interaction of metal vapour and welding gas considerably impacts the arc profile and, consequently, the heat transfer to the weldpool. Optical emission spectroscopy has been applied to determine the radial profiles of the plasma temperature and iron vapour concentration, as well as their temporal behaviour in the arc period for different mixtures of Ar, O2 and CO2 as shielding gases. Both the absolute iron vapour density and the temporal expansion of the iron core differ considerably for the gases Ar + 8%O2, Ar + 18% CO2 and 100% CO2 respectively. Pronounced minimum in the radial temperature profile is found in the arc centre in gas mixtures with high Ar content under the presence of metal vapour. This minimum disappears in pure CO2 gas. Consequently, the temperature and electrical and thermal conductivity in the arc when CO2 is used as a shielding gas are considerably lower.

Up to now, the use of the electrical characteristics for process control is state of the art in gas metal arc welding (GMAW). The aim of the work is the improvement of GMAW processes by using additional information from the arc. Therefore, the emitted light of the arc is analysed spectroscopically and compared with high-speed camera images. With this information, a conclusion about the plasma arc and the droplet formation is reasonable. With the correlation of the spectral and local information of the plasma, a specific control of the power supply can be applied. A corresponding spectral control unit (SCU) is introduced.