Formation of molten droplets at a consumable anode in an electric welding arc

A theoretical dynamic model has been developed to predict the formation of molten droplets on a moving wire electrode in a gas metal welding arc. Calculations have been made of the droplet shape and size as a function of the welding current by accounting for the electromagnetic pinch effect, surface tension, gravitation and momentum transfer due to motion of the solid wire electrode. Our calculations start with an artificial cylindrical liquid column which, for low currents, develops into a droplet which is close to spherical. However, for currents above about 250 A, the magnetic pinch constricts the column such that a smaller elongated droplet is formed.