Simulation of flux-wall guided transfer in submerged arc welding using two-dimensional particle method
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The flux-wall guided transfer, which is a specific molten metal droplet transfer mode in submerged arc welding, was modelled by an incompressible smoothed particle hydrodynamics method [1] and simulated in two dimensions. In this model, some driving forces such as Lorentz force and shearing force with plasma flow were calculated using computational results obtained by grid-based arc simulation [2]. Moreover, numerical experiments were carried out in order to clarify the dominant driving forces acting on the molten metal for this metal transfer mode. As a result, the flux-wall guided transfer was successfully simulated, in which the molten metal droplet left the wire tip while hitting a cavity wall. This computational result showed that a liquid column at the wire tip was formed by the Lorentz force, and then the column was pushed up by the cavity pressure and grown horizontally. Then, it collided with the cavity wall and molten metal droplets detached from the wire tip, and were transported toward weld pool and base metal. Numerical experiments using this computational model showed that when Lorentz force or cavity pressure was ignored, flux-wall guided transfer was not obtained. Therefore, it was suggested that both Lorentz force and cavity pressure were dominant driving forces for this metal transfer mode.