A two dimensional mathematical model has been developed for describing the temperature, flow, and electric fields in the are column of the Gas Metal Arc Welding (GMAW) of aluminum in argon shielding gas using axisymmetric Navier-Stokes, Maxwell, and differential thermal energy equations. The predicted results are most sensitive to the cathode spot radius and an optimum cathode spot radius exists on the basis of the minimum arc power consumption. The consumable electrode shape change due to droplet detachment is simulated in a quasi-steady manner using different electrode diameters. The change in electric field profile with different electrodes gives rise to large changes in flow conditions. This flow perturbation plus the non-uniform and transient J*B force field are suspected to enhance the recoil experience by the droplet on detachment, thus leading to violent and chaotic metal transfer in GMAW.

Keywords: Non, thermionic cathode, Metal transfer, GMAW modeling, Cathode spot size, Consumable electrode