An improved simulation model for three-wire gas metal arc welding

A three-dimensional numerical model was established to improve the accuracy of simulation with stationary three-wire GMAW method. High-speed photography was utilized to detect the details of welding process. The effective radius for arcs was calculated by Abel inversion method. Besides, due to arc interference, transverse velocities of droplets were added by a theoretical calculation method. The simulated longitudinal cross-sectional welded shape indicated good corresponding to the optical result. Moreover, the flow pattern of simulated results accorded well with the reality. According to the simulation, there existed upward mobility in the leading and trailing pools which can be attributed to the droplet impact. This mobility can cause the accumulation of molten metal at the side near middle pool. Therefore, it will accelerate the process to form common weld pool.