Numerical analysis of metal transfer in gas metal arc welding

G. Wang, P. G. Huang, Y. M. Zhang

Research output: Contribution to journalReview articlepeer-review

41 Scopus citations


The present article describes a numerical procedure to simulate metal transfer and the model will be used to analyze the transport processes involved in gas metal arc welding (GMAW). Advanced Computational fluid dynamics (CFD) techniques used in this model include a two-step projection method for solving the incompressible fluid flow; a volume of fluid (VOF) method for capturing free surface; and a continuum surface force (CSF) model for calculating surface tension. The electromagnetic force due to the welding current is estimated by assuming several different types of current density distribution on the free surface of the drop. The simulations based on the assumption of Gaussian current density distribution show that the transition from globular to spray transfer mode occurs over a narrow current range and the size of detached drops is nonuniform in this transition zone. The analysis of the calculation results gives a better understanding of this physical procedure. Comparisons between calculated results and experimental results are presented. It is found that the results computed from the Gaussian assumption agree well with those observed in experiments.

Original languageEnglish
Pages (from-to)345-353
Number of pages9
JournalMetallurgical and Materials Transactions B: Process Metallurgy and Materials Processing Science
Issue number3
StatePublished - Jun 2003

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Mechanics of Materials
  • Metals and Alloys
  • Materials Chemistry


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