Three-dimensional finite element modeling of pulsed AC gas metal arc welding process

The behavior of the welding arc in the pulsed DC and AC gas metal arc welding processes was studied using real-time recorded current, voltage waveforms, and synchronized high-speed video at different electrode negative (EN) ratios for a constant wire feed rate. The regression equations were developed to predict the arc root dimensions as a function of welding current, voltage, time, and the EN ratio. A methodology was proposed to estimate the available energy rate distribution to the electrode and the base plate during the positive and negative cycles in pulsed AC gas metal arc welding (pulsed AC-GMAW) process. For an approximately equal peak positive current, the increase in the pulse time enhanced the molten electrode droplet diameter, arc plasma distribution, and the arc root dimensions. The fraction of the available arc energy rate supplied to the base plate was higher in positive pulse when compared to the negative pulse. A three-dimensional finite element modeling of pulsed DC-GMAW and pulsed AC-GMAW processes was performed to estimate the weld pool profile and temperature distribution in the weldment. The computed weld width, penetration, and the thermal cycles were in reasonable agreement with the corresponding experimental results. The peak temperature of the region in the weld pool near to the Gaussian distributed heat source experience fluctuations which were in synchronization with the current waveform. Increase in the EN ratio decreased the peak temperature while increased the cooling rate in the weldment. This reduced the bainite phase and enhanced the martensite phase in the weldment.