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A theoretical study of a gas metal arc welding system

A theoretical model of a gas metal arc welding system has been developed to make predictions of the anode temperature profile, welding arc length and arc current. The model incorporates a one-dimensional thermal model of the moving consumable anode and a two-dimensional model for the arc plasma. The model makes possible the calculation of the relationship between the welding arc current, wire feed rate and the supply voltages, for various wire diameters and shielding gases. The predicted welding current for a given wire feed rate shows good agreement with our experimental observation for operation in the spray transfer mode, for steel wire of two different diameters, assuming a workpiece sheath voltage of 15 V.