Determination of Parameters of Electrode Metal Transported Drops by Simulation and Visualization

The nature of the molten electrode metal melting and transfer is the main process parameter of manual metal arc welding (MMA) with coated electrodes. It significantly affects the efficiency of the welding process. For this reason the relevant task is to identify the parameters of the transferred molten electrode metal drops and their further transfer into the weld pool with maximum accuracy. The aim of the given paper is to develop a method and visual representation of the form and the geometrics (volume, area, mass) of a molten electrode metal drop.

We have developed the method of simulation modeling and visualization for molten electrode metal drops transfer and their parameters. It allows obtaining highly reliable input data to be used for developing and verification of mathematical models for the thermal fields distribution along the welded item surface. The algorithm is realized as the calculation programs for specifying the molten metal drop parameters and means of its geometrics and space form visualization.

We used this method to specify a number of molten electrode metal drop parameters: volume, mass, center-of-gravity position, surface area.

We have established that it is possible to conduct the measurements with maximum

The suggested method significantly decreases the labor intensity of experimental studies aimed at specifying the size of electrode metal drops in comparison to the standard methods. When we know the size of the drops under certain welding conditions we can control the drop transfer process, i. e. reduce the heat input into the welded item and produce weld joints with the tailored performance characteristics.

1. Saraev Y.N., Chinakhov D.A., Ilyashchenko D.I., Kiselev A.S., Gordynets A.S. Investigation of the stability of melting and electrode metal transfer in consumable electrode arc welding using power sources with different dynamic characteristics. Welding International, 2017, no. 31(10), pp. 784−790. DOI: 10.1080/09507116.2017.1343977

2. Milyutin V.S. Ispytaniya svarochnyh svojstv oborudovaniya dlya dugovoj svarki [Testing the welding properties of equipment for arc welding]. Ekaterinburg, 2019, 466 p.

3. Lebedev V. Determination of the volume of the different drop of electrode metal in the conditions of vibrations of the bath and electrodewith arc mechanized welding. Нові матеріали і технології в металургії та машинобудуванні, 2017, no. 2, pp. 95−99 (in Ukrainian).

4. Makarenko V.D., Paly R.V., Mukhin M Yu. Tekhnologicheskie svojstva montazhnoj svarki truboprovodov [Technological properties of assembly welding of pipelines]. ed. V.D. Makarenko. Moscow: NedraBusiness Center LLC Publ., 2001, 118 p.

5. Krampit A.G., Krampit N.Yu. Method for determining the geometric dimensions and area of the weld. Welding production, 2012, no. 10, pp. 40–42.

6. Votinova E.B., Shalimov M.P. Appication of the complete material balance method to estimate the transition of elements in flux cored arc welding. Solid State Phenomena, 2020, vol. 299 SSP, pp. 559–564.

7. Makarenko V.D., Shatilo S.P. Calculation of the kinetic characteristics of electrode droplets during their passage through the arc gap during welding with coated electrodes. Welding production, 1999, no. 12, pp. 6–10.

8. Il’yaschenko D.P., Chinakhov D.A., Kirichenko K.Y., Sydorets V.N. Mathematical formula to determine geometrical dimensions of electrode metal droplets transferred with short circuits. Materials Science Forum, 2018, vol. 938, pp. 1−6. DOI: 10.4028/www.scientific.net/MSF.938.1

9. Ilyashchenko D.P., Berg V.I., Kryukov A.B., Saranchin A.A. Numerical simulation of thermal processes in welding with pulsed electrode wire feeding. Materials Science Forum, 2018, vol. 927 MSF, pp. 55−63. DOI: 10.4028/www.scientific.net/MSF.927.55

10. Chiocca A., Frendo F., Bertini L. Evaluation of heat sources for the simulation of the temperature distribution in gas metal arc welded joints. Metals, 2019, vol. 9(11), p. 1142. DOI: 10.3390/met9111142

11. Yonggang Z., Yanhong Z. High accuracy Numerical simulation on 3D weld-pool shape of large parts. Journal of Physics: Conference Series, 2019, vol. 1187(3), pp. 032−055. DOI: 10.1088/1742-6596/1187/3/032055

12. Votinova E.B., Shalimov M.P. Application of the complete material balance method to estimate the composition of weld metal in manual arc welding. Solid State Phenomena, 2017, vol. 265 SSP, pp. 762−766. DOI: 10.4028/www.scientific.net/SSP.265.762