Investigation of molten pool oscillation during GMAW-P process based on a 3D model

In order to better reveal the oscillation mechanism of the pulsed gas metal arc welding (GMAW-P) process due to an alternately varied welding current, arc plasma and molten pool oscillation were simulated through a self-consistent three-dimensional model. Based on an experimental analysis of the dynamic variation of the arc plasma and molten pool captured by a high-speed camera, the model was validated by comparison of the measured and predicted results. The calculated results showed that arc pressure was the key factor causing the molten pool to oscillate. The variation in arc size and temperature from peak time to base time resulted in a great difference in the heat input and arc pressure acting on the molten pool. The surface deformation of the molten pool due to the varying degrees of arc pressure induced alternate displacement and backflow in the molten metal. The periodic iteration of deeper and shallower surface deformation, drain and backflow of molten metal caused the molten pool to oscillate at a certain frequency. In this condition, the arc pressure at the peak time is more than six times higher than that at the base time, and the maximum surface depression is 1.4 mm and 0.6 mm, respectively, for peak time and base time.