Thermal Finite Element Formulation and Solution Versus Experimental Results for Thin-Plate GTA Welding

The problem of steady-state and transient heat transport associated with thin-plate welding is formulated and solved using the finite element method. Phase change is accurately accounted for through an element phase property averaging and quadratic/integral capacitance fitting technique. Three cases of quasi-steady welding of SS (stainless steel) 304 plates were simulated: input powers of 285, 405, and 588 W with corresponding velocities of 0.408 × 10⁻³, 1.270 × 10⁻³, and 2.540 × 10⁻³ m/s. Comparison to experimental results shows good agreement of weld pool size with a shape discrepancy developing as welder power and velocity increase. Arc heat flux and weld pool convection effects are discussed. A review of these results, combined with a survey of current literature, enabled possible causes of these weld pool shape differences to be identified and enabled recommendations for future research to be made.