Dynamic analysis of droplet transfer in gas–metal arc welding: modelling and experiments

In this work, a pulsed welding process is investigated to highlight how a time-varying profile of current impacts the metal transfer dynamics. First, the process is recorded using a high-speed camera, allowing us to qualitatively evaluate the effectiveness of metal transfer and the synchronization of droplet detachment with current peaks. Second, a time-dependent axisymmetric 2D model is developed to take into account both the droplet detachment using a volume-of-fluid model and the production and diffusion of metal vapour through a simplified diffusion model (neglecting demixing effects). We report a comparison between experimental and simulative results of a pulsed transfer mode for a steel wire (φ = 1 mm) and Ar shielding gas. (paper)