Development of Free Surface Tracking Algorithms for Fusion Welding Simulations

Most previous welding simulations are based on a flat weld pool surface and become unmeaningful when the surface deformation is significant. In recent years, some researchers have developed numerical models capable of simulating free surface motion in welding processes, but they focus on the discussions of physical equations, boundary conditions, and solutions, rather than the numerical algorithms. Engineers may find it difficult to reproduce these studies without considerable effort. In this paper, we develop an easy to follow numerical procedure for the simulation of fusion welding processes. Recommendations are made on the selection and implementation of numerical algorithms, while alternative methods are also reviewed. The simulation algorithms posed here are efficient and robust. They can simulate gas metal arc welding, gas tungsten arc welding, laser welding and plasma arc welding.