3D Numerical Study of External Axial Magnetic Field-Controlled High-Current GMAW Metal Transfer Behavior

Xiao, Lei; Fan, Ding; Huang, Jiankang; Tashiro, Shinichi; Tanaka, Manabu

doi:10.3390/ma13245792

Open AccessArticle

3D Numerical Study of External Axial Magnetic Field-Controlled High-Current GMAW Metal Transfer Behavior

by

Lei Xiao

¹

,

Ding Fan

^2,*,

Jiankang Huang

^3,*

,

Shinichi Tashiro

^4,*

and

Manabu Tanaka

⁴

¹

School of Materials Science and Engineering, Lanzhou Jiaotong University, Lanzhou 730070, China

²

State Key Laboratory of Advanced Processing and Recycling of Non-ferrous Metals, Lanzhou University of Technology, Lanzhou 730050, China

³

School of Materials Science and Engineering, Lanzhou University of Technology, Lanzhou 730050, China

⁴

Joining and Welding Research Institute, Osaka University, Osaka 5670047, Japan

^*

Authors to whom correspondence should be addressed.

Materials 2020, 13(24), 5792; https://doi.org/10.3390/ma13245792

Submission received: 17 November 2020 / Revised: 15 December 2020 / Accepted: 15 December 2020 / Published: 18 December 2020

(This article belongs to the Collection Welding and Joining Processes of Materials)

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Abstract

For gas metal arc welding (GMAW), increasing the welding current is the most effective way to improve welding efficiency. However, much higher current decreases the welding quality as a result of metal rotating-spray transfer phenomena in the high-current GMAW process. In this work, the external axial magnetic field (EAMF) was applied to the high-current GMAW process to control the metal transfer and decrease the welding spatters. A unified arc-droplet coupled model for high-current GMAW using EAMFs was built to investigate the metal rotating-spray transfer behavior. The temperature fields, flow fields in the arc, and droplet were revealed. Considering all the heat transferred to the molten metal, the Joule heat was found to be the dominant factor affecting the droplet temperature rise, followed by the anode heat. The conductive heat from the arc contributed less than half the value of the other two. Considering the EAMFs of different alternating frequencies, the arc constricting effects and controlled metal transfer behaviors are discussed. The calculated results agree well with the experimental high-speed camera observations.

Keywords: gas metal arc welding; high-efficiency; external axial magnetic field; numerical simulation; metal rotating-spray transfer; spatter

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MDPI and ACS Style

Xiao, L.; Fan, D.; Huang, J.; Tashiro, S.; Tanaka, M. 3D Numerical Study of External Axial Magnetic Field-Controlled High-Current GMAW Metal Transfer Behavior. Materials 2020, 13, 5792. https://doi.org/10.3390/ma13245792

AMA Style

Xiao L, Fan D, Huang J, Tashiro S, Tanaka M. 3D Numerical Study of External Axial Magnetic Field-Controlled High-Current GMAW Metal Transfer Behavior. Materials. 2020; 13(24):5792. https://doi.org/10.3390/ma13245792

Chicago/Turabian Style

Xiao, Lei, Ding Fan, Jiankang Huang, Shinichi Tashiro, and Manabu Tanaka. 2020. "3D Numerical Study of External Axial Magnetic Field-Controlled High-Current GMAW Metal Transfer Behavior" Materials 13, no. 24: 5792. https://doi.org/10.3390/ma13245792

APA Style

Xiao, L., Fan, D., Huang, J., Tashiro, S., & Tanaka, M. (2020). 3D Numerical Study of External Axial Magnetic Field-Controlled High-Current GMAW Metal Transfer Behavior. Materials, 13(24), 5792. https://doi.org/10.3390/ma13245792

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3D Numerical Study of External Axial Magnetic Field-Controlled High-Current GMAW Metal Transfer Behavior

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