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Heat and metal transfer in gas metal arc welding using argon and helium

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Abstract

This article describes a theoretical investigation on the arc parameters and metal transfer in gas metal arc welding (GMAW) of mild steel using argon and helium shielding gases. Major differences in the predicted arc parameters were determined to be due to large differences in thermophysical properties. Various findings from the study include that an arc cannot be struck in a pure helium atmosphere without the assistance of metal vapor, that a strong electromagnetic cathode force affects the fluid flow and heat transfer in the helium arc, providing a possible explanation for the experimentally observed globular transfer mode and that the tapering of the electrode in an argon arc is caused by electron condensation on the side of the electrode.

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Abbreviations

Bθ :

self-induced azimuthal magnetic field (Wb/m2)

C p :

specific heat at constant pressure (J/kg K)

e :

elementary charge (As)

F r :

radial Lorentz force (N/m3)

F z :

axial Lorentz force (N/m3)

h :

plasma enthalpy (J/kg)

h a :

anode enthalpy (J/kg)

h c,i :

enthalpy within the cathode spot region (J/kg)

h c,o :

enthalpy outside the cathode spot region (J/kg)

h i :

enthalpy of gas flowing into the system (J/kg)

I :

welding current (A)

J :

current density (A/m2)

J c :

cathode current density (A/m2)

J r :

radial current density (A/m2)

J z :

axial current density (A/m2)

k :

thermal conductivity (W/m K)

kg :

Boltzmann’s constant (J/K)

k g :

thermal conductivity in the anode fall region(W/m K)

tP:

pressure (Pa)

kQ a :

heat lost by the gas in the anode fall region (W/m2)

Q c :

heat gained by the gas in the cathode fall region (W/m )

r :

radial distance (m)

R c :

cathode spot (weld pool) radius (m)

S R :

radiation loss term (W/m3)

T :

temperature (K)

T a,g :

temperature in the gas at a distanced from the anode (K)

T an :

anode temperature (K)

T av :

average temperature of gas in the anode fall region (K)

T c,e :

decrease in electron temperature at the cathode (K)

T c,g :

temperature in the gas at a distance 0.1 mm from the cathode (K)

Tcat :

cathode temperature (K)

u :

radial velocity (m/s)

V c :

cathode fall voltage (V)

w :

axial velocity (m/s)

z:

axial distance (m)

δ:

thickness of anode fall region (m)

μ:

molecular dynamic viscosity (Kg/ms)

0 :

magnetic permeability of free space (H/m)

ρ:

density (kg/m3)

δe :

electrical conductivity (1/Wm)

Φ:

electric potential (V)

Φmax :

maximum value of the electric potential (V)

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Author information

Authors and Affiliations

  1. MEFOS, Luleå, Sweden

    P. G. Jönsson (Head of Secondary Metallurgy Group)

  2. Department of Materials Science and Engineering, Massachusetts Institute of Technology, 02139, Cambridge, MA

    T. W. Eagar (Professor) & J. Szekely (Professor)

Authors
  1. P. G. Jönsson
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  2. T. W. Eagar
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  3. J. Szekely
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Formerly Graduate Student, Massachusetts Institute of Technology

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Jönsson, P.G., Eagar, T.W. & Szekely, J. Heat and metal transfer in gas metal arc welding using argon and helium. Metall Mater Trans B 26, 383–395 (1995). https://doi.org/10.1007/BF02660980

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  • DOI: https://doi.org/10.1007/BF02660980

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