Analysis of submerged arc welding process by three-dimensional computational fluid dynamics simulations

The effect of torch angle and current polarities on the convection heat transfer in single wire submerged arc welding is analyzed. To develop arc models such as arc heat flux, arc pressure and electromagnetic force, this study adopts the Abel inversion method with CCD camera images for direct and alternating current polarities. The heat transfer by molten slag from the flux consumption is considered as an additional boundary heat source in the numerical simulation. The variation of arc forces, the direction of droplet flight with polarity and the torch angle significantly affect the molten pool flow and the resultant weld beads. The simulated weld pool profiles are validated with corresponding experimental results and found to be in good agreement.