Three-dimensional numerical simulation of slag formation and transfer processes in metal active gas welding using incompressible smoothed particle hydrodynamics method

  • Komen, Hisaya (Osaka University)
  • Fukazawa, Takamasa (Osaka University)
  • Shigeta, Masaya (Tohoku University)
  • Tanaka, Manabu (Osaka University)
  • Yamada, Tetsuo (Mazda Motor Corporation)
  • Saito, Naoko (Mazda Motor Corporation)
  • Fukahori, Mitsugi (Mazda Motor Corporation)

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Slag formation and transfer processes during a metal active gas welding which was one of arc welding methods was modelled by an incompressible smoothed particle method [1] with a two-fluid model [2]. Then, numerical simulations were performed to clarify dominant factors for the slag transfer process. As a result, slags were formed on a weld pool surface near the centre of a heat source where arc temperature and mole fraction of oxygen were high, and they were transported to backward of the pool along its edge. These series of slag behaviours were also observed in actual welding using a high-speed video camera, indicating validity of this computational model. From computational results, velocity distribution of the slag showed same tendency compared with that of the molten metal. This indicated that slags on the weld pool surface were transported by the molten metal. Moreover, from driving force distributions of the molten metal, it was clarified that slags located near the heat source centre were transported to the weld pool edge by the force due to the Marangoni effect, the shearing force and the molten metal droplet transfer. On the other hand, slags located near backward of the pool were transported by the force due to the Marangoni effect.