A simulation-based approach to characterise melt-pool oscillations during gas tungsten arc welding

Development, optimisation and qualification of welding additive manufacturing procedures to date have largely been undertaken on an experimental trial error basis, which imposes significant costs. Numerical simulations are acknowledged as a promising alternative experiments, can improve the understanding complex process behaviour. In present work, we propose simulation-based approach study characterise molten metal melt pool oscillatory behaviour during arc welding. We implement high-fidelity three-dimensional model based finite-volume method that takes into account effects surface deformation power-density force distributions. These factors often neglected in numerical manufacturing. Utilising this model, predict flow pools associated melt-pool oscillations both steady-current pulsed-current gas tungsten (GTAW). An analysis wavelet transform was performed extract time-frequency content displacement signals obtained from simulations. Our results confirm frequency for fully penetrated is lower than partially with abrupt change partial full penetration. find transition penetration state, two dominant frequencies coexist spectrum. The demonstrate profoundly depend shape convection pool, turn influenced by parameters material properties. reveal unsteady evolution not predictable published theoretical analyses. Additionally, using proposed approach, need triggering expendable since even small displacements detectable, sensible current measurement devices employed experiments.