A dynamic model of droplet formation in GMA welding

Semenov, Oleksii; Demchenko, V.; Krivtsun, I.V.; Reisgen, Uwe; Mokrov, Oleg; Zabirov, Alexander

doi:10.1088/0965-0393/20/4/045003

Cited by 8 publications

(6 citation statements)

References 14 publications

(40 reference statements)

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“…A wide variety of flows involving droplets, jets, and films exist in many processes of production engineering, e.g., Gas Metal Arc Welding (GMAW) [4]. In GMAW problems, droplets of molten metal detach from the electrode, driven by electromagnetic forces and heating, and impact a weld seam.…”

Section: Introductionmentioning

confidence: 99%

Axisymmetric two‐phase flow simulations on space‐time meshes

Karyofylli

Kamaldinova

Simon

et al. 2019

Proc Appl Math and Mech

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For reducing the dimensionality and consequently, the complexity of the dynamics related to bubble formation problems, this paper presents an axisymmetric space-time interface capturing approach [1,2]. For the description of the moving front, the level-set method is used, because it is inherently able to account for topological changes of the interface [3], and is combined with a continuum surface force (CSF) model. Different benchmark cases from the literature are used for verifying our numerical approach, and the results are compared with those obtained using the commercial software, ANSYS CFX.

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Section: Introductionmentioning

confidence: 99%

Axisymmetric two‐phase flow simulations on space‐time meshes

Karyofylli

Kamaldinova

Simon

et al. 2019

Proc Appl Math and Mech

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“…The second group of models includes a model of droplet formation within the hydrostatic approximation [9], thin jet approximation [10] and the model based on the Navier-Stokes, Maxwell's and thermal conductivity equations [11]. The essence of the problems addressed in this model is to determine the shape and volume of a maximum stable droplet.…”

Section: Introductionmentioning

confidence: 99%

“…The model using the thin jet approximation [10] is based on the following assumptions: 1) the melting front is considered to be flat; 2) the wire feed speed corresponds to the speed of its melting; 3) there is no swirling motion of a droplet inside the droplet; 4) the form of the arc column is considered to be given. Solution of Navier-Stokes equations in this approximation allows observing the dynamics of the droplet formation and its detachment.…”

Section: Introductionmentioning

confidence: 99%

Model of formation of droplets during electric arc surfacing of functional coatings

Sarychev

Granovskii

Невский

et al. 2016

AIP Conference Proceedings

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Predictions of metal droplet formation in gas metal arc welding. II. Journal of Applied Physics 84, 3530 (1998) Abstract. The mathematical model was developed for the initial stage of formation of an electrode metal droplet in the process of arc welding. Its essence lies in the fact that the presence of a temperature gradient in the boundary layer of the molten metal causes thermo-capillary instability, which leads to the formation of electrode metal droplets. А system of equations including Navier-Stokes equations, heat conduction and Maxwell's equations was solved as well as the boundary conditions for the system electrodes-plasma. Dispersion equation for thermo-capillary waves in the linear approximation for the plane layer was received and analyzed. The values of critical wavelengths, at which thermocapillary instability appears in the nanometer wavelength range, were found. The parameters at which the mode of a finedroplet transfer of the material takes place were theoretically defined.

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“…The second group includes the model of drop formation in terms of hydrostatic approximation [9][10][11], as well as models based on equations of motion of viscous incompressible liquid. In its turn, in the subgroup of dynamic models thin jet approximation can be singled out [12][13][14], as well as models based on total system of Navier-Stokes equations [15][16][17][18][19][20]. Let us consider the most widely accepted of the above methods.…”

mentioning

confidence: 99%

“…Model using total system of Navier-Stokes equations to describe hydrodynamic processes in the drop requires numerical realization of considerable computational resources that limits its application in a massive numerical experiment. Thin jet approximation [26], adapted to consumable electrode welding conditions [14], is considered as an alternative to this model. The following hypotheses were used in development of this model:…”

mentioning

confidence: 99%

Methods of mathematical modelling of the processes of electrode metal drop formation and transfer in consumable electrode welding (Review

Semyonov¹,

Paton²

2014

The Paton Welding J.

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Processes of welding wire heating and melting, electrode metal drop formation and transfer in consumable electrode welding largely determine welding efficiency and quality. In its turn, the nature of metal melting and transfer with this welding process is determined by a large number of such physical phenomena as heat and mass transfer, gas(hydro)dynamics, electromagnetic processes, running in arc plasma, on the surface and in the volume of molten electrode metal-drop. This paper gives a review of currently available methods of theoretical investigation and mathematical modelling of the above processes, allowing prediction of such characteristics of electrode metal transfer as drop volume and shape, their thermal and gas-dynamic state, detachment frequency, etc. Advantages and disadvantages of the considered models are analyzed and main directions of their further development are outlined. 37 Ref.,11 Figures. K e y w o r d s : consumable electrode welding, mathematical modelling, electrode metal drop formationInterest to the problem of metal transfer in consumable electrode welding is due to a number of causes. It is known that formation of electrode metal drop can be accompanied by its overheating, leading to considerable loss of alloying elements contained in welding wire, bulk boiling and spattering of drop metal, closing of arc gap, etc. In addition, metal transfer mode essentially influences the processes running in the weld pool that, in its turn, determines weld formation. Ensuring directed metal transfer in welding in different positions is also important. Therefore, this work sets forth the known theoretical approaches and describes the available mathematical models, allowing prediction of the main characteristics of metal transfer at different technological parameters of consumable electrode welding.Methods of mathematical modelling of drop formation and electrode metal transfer in consumable electrode welding can be conditionally divided into two main groups (Figure 1). The first includes approaches, which enable prediction of just the individual characteristics of metal transfer process, such as drop size and detachment frequency. The main disadvantage of these models consists in that they do not allow determination of drop shape, or describing the phenomena of charge and energy transfer in molten electrode metal, which accompany the considered technological process. The first group includes such procedures as static force balance theory (SFBT) [1][2][3], pinch instability theory (PIT) [4][5][6], as well as dynamic force balance theory (DFBT) [7,8]. The second group includes the model of drop formation in terms of hydrostatic approximation [9-11], as well as models based on equations of motion of viscous incompressible liquid. In its turn, in the subgroup of dynamic models thin jet approximation can be singled out [12][13][14], as well as models based on total system of Navier-Stokes equations [15][16][17][18][19][20]. Let us consider the most widely accepted of the above methods.SFBT. This method is...

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A dynamic model of droplet formation in GMA welding

Cited by 8 publications

References 14 publications

Axisymmetric two‐phase flow simulations on space‐time meshes

Axisymmetric two‐phase flow simulations on space‐time meshes

Model of formation of droplets during electric arc surfacing of functional coatings

Methods of mathematical modelling of the processes of electrode metal drop formation and transfer in consumable electrode welding (Review

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