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Visualization of arc plasma and molten wire behavior in CO2 arc welding process by three-dimensional numerical simulation

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Abstract

In the CO2 welding process, a consumable wire electrode is used and metal transfer phenomena are involved. However, when the arc current is high, the molten wire behavior becomes unstable, and it leads to a large degree of spattering. In this study, a three-dimensional unified model comprising both the arc plasma and the molten wire was constructed, and the behavior of them was visualized using numerical simulations. The transfer mode is regarded as globular transfer in the numerical simulation with an arc current of 300 A. In addition, when the molten metal droplet becomes asymmetrical, the molten wire is pushed up by the arc plasma, and the transfer mode becomes repelled transfer. The temperature distribution and the metal vapor concentration distributions in the symmetrical and asymmetrical cases are significantly different. When the droplet shape is close to symmetrical, the metal vapor concentrates at the center of the arc plasma and the overall temperature of the arc plasma decreases. In contrast, when the droplet shape is asymmetrical, the high-temperature region and metal vapor region are separated. The numerical results showed that the properties of the arc plasma are significantly changed depending on the molten wire behavior.

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Funding

This research was supported by JSPS KAKENHI Grant Number JP19K15323.

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  1. Graduate School of Engineering, Osaka University, 2-1 Yamada-oka, Suita, Osaka, Japan

    Y. Ogino, S. Asai & Y. Hirata

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  1. Y. Ogino
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  2. S. Asai
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  3. Y. Hirata
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Correspondence to Y. Ogino.

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Ogino, Y., Asai, S. & Hirata, Y. Visualization of arc plasma and molten wire behavior in CO2 arc welding process by three-dimensional numerical simulation. Weld World 64, 1789–1797 (2020). https://doi.org/10.1007/s40194-020-00958-4

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  • DOI: https://doi.org/10.1007/s40194-020-00958-4

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