Numerical Simulation and Experimental Study on the Influence of Gap Width in GTAW Welding on Arc Climbing Mechanism

LI Yuechao; WANG Lei; QIAO Jisen

doi:10.7512/j.issn.1001-2303.2025.09.05

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Numerical Simulation and Experimental Study on the Influence of Gap Width in GTAW Welding on Arc Climbing Mechanism
Vol. 55, Issue 9, Pages: 59-68(2025)
Received：20 June 2024，

Revised：2024-12-02，

Published：20 September 2025
DOI： 10.7512/j.issn.1001-2303.2025.09.05
稿件说明：

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李越超，王磊，乔及森.GTAW焊接坡口间隙对电弧攀升影响机制数值模拟与实验研究［J］.电焊机，2025，55（9）：59-68. DOI： 10.7512/j.issn.1001-2303.2025.09.05.

LI Yuechao, WANG Lei, QIAO Jisen.Numerical Simulation and Experimental Study on the Influence of Gap Width in GTAW Welding on Arc Climbing Mechanism[J].Electric Welding Machine, 2025, 55(9): 59-68. DOI： 10.7512/j.issn.1001-2303.2025.09.05.

摘要

基于计算流体力学，建立了一个针对超窄间隙（<8 mm）钨极氩弧焊（GTAW）过程的稳态三维数值模型，以研究不同坡口宽度下电弧的特性。通过计算获得了不同坡口宽度下GTAW焊接电弧的温度场、速度场和压力场等结果，结果揭示了等离子体的温度、坡口表面压力分布、坡口表面电流密度分布与坡口宽度大小的关系。通过对比分析不同坡口宽度下的计算结果，发现在钨极直径为1.6 mm，坡口宽度小于7 mm的条件下，电弧主要通过侧壁传导，其主要热作用也集中在侧壁上。而当坡口宽度在7 mm时，电弧开始与坡口底部导通，由于电弧压缩效应，在坡口底部出现局部高温和高电流密度区域，通过模拟发现针对该特定接头，为阻止电弧攀升的临界坡口间隙为7 mm。进一步，当坡口间隙为8 mm时，电弧全部集中作用于坡口底部，并在焊缝根部形成涡流，这有利于焊缝根部的熔合。在实验中，采用高速摄像系统记录不同坡口宽度下电弧的形态，发现其与模拟结果吻合良好。

Abstract

Based on computational fluid dynamics

a steady-state three-dimensional numerical model was established for the tungsten inert gas arc welding (GTAW) process in ultra-narrow gaps (<8 mm) to investigate the characteristics of the arc under different groove widths. Through calculations

the temperature field

velocity field

and pressure field of the GTAW welding arc were obtained for different groove widths

revealing the relationship between the groove width and the temperature of the plasma

the pressure distribution on the groove surface

and the current density distribution on the groove surface. By comparing and analyzing the calculation results for different groove widths

it was found that when the tungsten electrode diameter is 1.6 mm and the groove width is less than 7 mm

the arc mainly conducts through the sidewalls

and its primary thermal action is also concentrated on the sidewalls. However

when the groove width is 7 mm

the arc begins to conduct with the groove bottom

and due to the arc compression effect

a localized high-temperature and high-current density area appears at the groove bottom. Through simulation

it was found that for this specific joint

the critical groove gap to prevent arc climbing is 7 mm. Furthermore

when the groove gap is 8 mm

the arc is fully concentrated on the groove bottom

forming a vortex at the weld root

which is beneficial for the fusion of the weld root. In the experiment

a high-speed camera system was used to record the arc morphology under different groove widths

and it was found to match the simulation results well.

关键词

Keywords

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