FEA based prediction of weld dimension in new DE-GMAW process

Double-electrode gas metal arc welding (DE-GMAW) is a novel arc welding process with high efficiency. In DE-GMAW, the MAG arc is the main arc while the TIG arc is a bypass arc. Because the TIG arc takes away some current, the current flowed on the base metal is decreased based on the premise that the total current is constant. Thus, the deposition rate can be guaranteed and the heat input to the base metal is reduced. The high deposition rate and high speed welding could be realized in DE-GMAW. With considering the process characteristics of the new DE-GMAW, a finite element analysis (FEA) model is developed through extending the function of software SYSWELD, simplifying the processing method of weld reinforcement, and proposing the corresponding mode of welding heat source. Based on the FEA results of temperature profile in DE-GMAW, the weld dimension at cross section and temperature distribution are obtained. The predicted and experimental measured results match well, which lays the foundation for the process optimization of DE-GMAW.