Modelling of Gas Tungsten Arc Welding Pool under Marangoni Convection

Due to lack of comprehensive experimental studies on welding processes, and to better understand the mechanisms behind these processes, especially the weld pool shape variations suspected due to Marangoni Effect or surface tension shear stress, a two-dimensional simulation model was developed to study the physics of gas tungsten arc welding (GTAW). Experimental spot-welds on Ti-5Al-5Mo-5V-3Cr was carried out to compare to the model for crucial clues such as, the magnitude of Marangoni convectional stress that is difficult to determine experimentally; and to estimate the Enhancement Factor, an artificial parameter incorporated into the model proven to account for any discrepancies between simulated results and experimental weld pool shapes, due to lack of viscosity temperature dependent data as well as flow instabilities. The model confirmed that Marangoni Convection is indeed the most dominant force in shaping the weld pool, followed by thermal buoyancy force and electromagnetic force. As the investigation went on, the validity of past welding simulations assuming a constant flow scheme was examined, concluding with the recommendation of applying a laminar flow regime at the initial welding times and turbulent flow with elapsing welding time to effectively eliminate simulation inaccuracies.