Comparative study of the main electromagnetic models applied to melt pool prediction with gas metal arc: Effect on flow, ripples from drop impact, and geometry
Artikel i vetenskaplig tidskrift, 2022

The present work concerns the electromagnetic force models in computational fluid dynamics simulations of melt pools produced with electric arcs. These are commonly applied to gas metal arcs with metal transfer, in welding and additive manufacturing. Metal drop impact on the melt pool is thus included in this study. The electromagnetic force models applied in literature use either numerical solutions of Poisson equations or one of the two analytical models developed by Kou and Sun, or Tsao and Wu. These models rely on assumptions for which the effect on the melt pool predictions remains to be understood. The present work thoroughly investigates those assumptions and their effects. It has been supported by dedicated experimental tests that did provide estimates of unknown model parameters and validation data. The obtained results show that the assumptions that fundamentally distinguish these three models change the electromagnetic force, including the relation between its components. These changes, which can also be spatially non-uniform, are large. As a result, these models lead to significantly different recirculation flow pattern, thermal convection, melt pool morphology, bead dimensions, and free surface response to the metal transfer. We conclude by proposing conditions in which each of these models is
suited or questionable.

Kou and Sun mode

Molten pool

Tsao and Wu model

Gas metal arc

Free surface oscillation

Maxwell electromagnetic force model

Metal transfer

Författare

Pradip Aryal

Högskolan Väst

Fredrik Sikström

Högskolan Väst

Håkan Nilsson

Chalmers, Mekanik och maritima vetenskaper, Strömningslära

Isabelle Choquet

Högskolan Väst

International Journal of Heat and Mass Transfer

0017-9310 (ISSN)

Vol. 194 123068

Drivkrafter

Hållbar utveckling

Styrkeområden

Produktion

Ämneskategorier

Bearbetnings-, yt- och fogningsteknik

Strömningsmekanik och akustik

Infrastruktur

C3SE (Chalmers Centre for Computational Science and Engineering)

DOI

10.1016/j.ijheatmasstransfer.2022.123068

Mer information

Senast uppdaterat

2022-11-23