Comparative Modeling of Heat and Mass Transfer in Manual and Gas Metal Arc Welding Including Heat Sources and Reacting Forces

The melting of the wire is a fundamental characteristic of Manual Metal Arc and Gas Metal Arc welding which influences process stability, productivity, and weld bead shape. The present work describes a model developed to calculate Heat and Mass transfer during the welding process including the effects of joule heating, Electron condensation, Cohesive and Magnetic forces. These forces have significant effects on the transient distributions of current density, Heat and mass transfer in Manual Metal Arc and Gas Metal Arc Welding. It has also been proven that physical properties of shielding gases and electrode covers affects some of arc characteristics like metal transfer, wetting behavior, depth of penetration, shape of penetration, travel speed and easy of arc starting. In this paper it has been shown that, proper doping of inert gases with reasonable amounts of active components such as CO2, NO or O2 results in better arc stabilization and therefore better heat and mass transfer. The dissociation energy of polyatomic components in gas mixtures enhance the heat input to the base material due to the energy released by recombination. If these results be fully utilized, failure of fabricated equipment in industries, especially SMEs will completely be eliminated. The results were compared to the results obtained from the experiments and various literatures.