Alireza Javidi Shirvan

A review of cathode-arc coupling modeling in GTAW

Material properties of welds are strongly influenced by the thermal history, including the thermo-fluid and electromagnetic phenomena in the weld pool and the arc heat source. A necessary condition for arc heat source models to be predictive is to include the plasma column, the cathode, and the cathode layer providing their thermal and electric coupling. Different cathode layer models based on significantly different physical assumptions are being used. This paper summarizes today’s state of the art of cathode layer modeling of refractory cathodes used in GTAW at atmospheric pressure. The fundamentals of the cathode layer and its physics are addressed. The main modeling approaches, namely (i) the diffusion approach, (ii) the partial LTE approach, and (iii) the hydrodynamic approach are discussed and compared. The most relevant publications are systematically categorized with regard to the respective physical phenomena addressed. Results and process understanding gained with these models are summarized. Finally, some open questions are underlined.

On the choice of electromagnetic model for short high-intensity arcs, applied to welding

We have considered four different approaches for modelling the electromagnetic fields of high-intensity electric arcs: (i) three-dimensional, (ii) two-dimensional axi-symmetric, (iii) the electric potential formulation and (iv) the magnetic field formulation. The underlying assumptions and the differences between these models are described in detail. Models (i) to (iii) reduce to the same limit for an axi-symmetric configuration with negligible radial current density, contrary to model (iv). Models (i) to (iii) were retained and implemented in the open source CFD software OpenFOAM. The simulation results were first validated against the analytic solution of an infinite electric rod. Perfect agreement was obtained for all the models tested. The electromagnetic models (i) to (iii) were then coupled with thermal fluid mechanics, and applied to axi-symmetric gas tungsten arc welding test cases with short arc (2, 3 and 5 mm) and truncated conical electrode tip. Models (i) and (ii) lead to the same simulation results, but not model (iii). Model (iii) is suited in the specific limit of long axi-symmetric arc with negligible electrode tip effect, i.e. negligible radial current density. For short axi-symmetric arc with significant electrode tip effect, the more general axi-symmetric formulation of model (ii) should instead be used.

Effect of cathode model on arc attachment for short high-intensity arc on a refractory cathode

Various models coupling the refractory cathode, the cathode sheath and the arc at atmospheric pressure exist. They assume a homogeneous cathode with a uniform physical state, and differ by the cathode layer and the plasma arc model. However even the most advanced of these models still fail in predicting the extent of the arc attachment when applied to short high-intensity arcs such as gas tungsten arcs. Cathodes operating in these conditions present a non-uniform physical state. A model taking into account the first level of this non-homogeneity is proposed based on physical criteria. Calculations are done for 5 mm argon arcs with a thoriated tungsten cathode. The results obtained show that radiative heating and cooling of the cathode surface are of the same order. They also show that cathode inhomogeneity has a significant effect on the arc attachment, the arc temperature and pressure. When changing the arc current (100 A, 200 A) the proposed model allows predicting trends observed experimentally that cannot be captured by the homogeneous cathode model unless restricting a priori the size of the arc attachment. The cathode physics is thus an important element to include to obtain a comprehensive and predictive arc model.

Coupling boundary condition for high-intensity electric arc attached on a non-homogeneous refractory cathode

The boundary coupling high-intensity electric arc and refractory cathode is characterized by three sub-layers: the cathode sheath, the Knudsen layer and the pre-sheath. A self-consistent coupling boundary condition accounting for these three sub-layers is presented; its novel property is to take into account a non-uniform distribution of electron emitters on the surface of the refractory cathode. This non-uniformity is due to cathode non-homogeneity induced by arcing. The computational model is applied to a one-dimensional test case to evaluate the validity of different modeling assumptions. It is also applied coupling a thoriated tungsten cathode with an argon plasma (assumed to be in local thermal equilibrium) to compare the calculation results with uniform and non-uniform distribution of the electron emitters to experimental measurements. The results show that the non-uniformity of the electron emitters’ distribution has a significant effect on the calculated properties. It leads to good agreement with the cathode surface temperature, and with the plasma temperature in the hottest region. Some differences are observed in colder plasma regions, where deviation from local thermal equilibrium is known to occur.

A physically based model for thermal plasma arc attachment on a W-ThO2 cathode

Summary form only given. Arc attachment radius imposed a priori when modelling the coupling between cathode, cathode layer and thermal plasma still hinders models from being predictive, as underlined in a recent review1. The aim of this work was to find a physical element, still lacking in the models, which could contribute in governing the arc attachment. In this study the cathode layer is modeled within the frame of the partial local thermal equilibrium approach1 including the space charge layer, the Knudsen layer and the ionization layer, while the plasma column is assumed to be in local thermal equilibrium. Several modeling assumptions were questioned based on e.g. contradictory assumptions in the literature, or oversimplified physics compared to experimental observations. For testing model and assumptions, 5 mm argon arc test cases with a sharp cathode geometry that have been investigated experimentally in the literature were calculated. Within this framework, the following conclusions were drawn. The space charge emitted electrons is negligible. The Richardson-Dushman emission law supplemented with Schottky correction is used within its domain of validity when applied to thorium doped tungsten cathodes, which are mainly characterized by a field enhanced thermionic emission regime. The radiative heat absorption from the plasma at the cathode surface is not negligible compared to the radiative emission. Ignoring the non-homogeneous structure and composition of a doped tungsten cathode operated in these conditions leads to a large over-estimation of the extent of the arc attachment, and results in an under-estimation of the arc temperature. A cathode model based on physical criteria for taking into account a first level of the cathode inhomogeneity has a significant effect on the arc attachment and on arc properties such as temperature and pressure. The cathode physics is thus an important element to include for obtaining a comprehensive and predictive arc model.