Arc interaction and molten pool behavior in the three wire submerged arc welding process

A three-dimensional numerical heat transfer and fluid flow model is developed to understand the temperature distribution and molten pool behavior in a three wire submerged arc welding process. The model solves the equations of the conservation of mass, momentum, and energy along with the volume of fluid method. The volume of fluid method is used to track the shape of the free surface. Further, a physical model is developed to estimate the arc center displacement. For a given welding condition, connecting the leading electrode with direct current electrode positive polarity, the middle and trailing electrodes with trapezoidal alternating current waveform displayed deeper weld pools when compared to the sine waveforms. Within the range of welding conditions considered in the present work, weld width is significantly influenced by the leading arc whereas the penetration by the middle and trailing arcs. The computed weld width and penetration are in fair agreement with the corresponding experimental results.