Computational modeling of stationary gastungsten-arc weld pools and comparison to stainless steel 304 experimental results

A systematic study was carried out to verify the predictions of a transient multidimensional computational model by comparing the numerical results with the results of an experimental study. The welding parameters were chosen such that the predictions of the model could be correlated with the results of an earlier experimental investigation of the weld pool surface temperatures during spot gas-tungsten-arc (GTA) welding of Type 304 stainless steel (SS). This study represents the first time that such a comprehensive attempt has been made to experimentally verify the predictions of a numerical study of weld pool fluid flow and heat flow. The computational model considers buoyancy and electromagnetic and surface tension forces in the solution of convective heat transfer in the weld pool. In addition, the model treats the weld pool surface as a truly deformable surface. Theoretical predictions of the weld pool surface temperature distributions, the cross-sectional weld pool size and shape, and the weld pool surface topology were compared with corresponding experimental measurements. Comparison of the theoretically predicted and the experimentally obtained surface temperature profiles indicated agreement within ±8 pct for the best theoretical models. The predicted surface profiles were found to agree within ±20 pct on dome height and ±8 pct on weld pool diameter for the best theoretical models. The predicted weld cross-sectional profiles were overlaid on macrographs of the actual weld cross sections, and they were found to agree very well for the best theoretical models.