A dynamic model of droplet formation in GMA welding

A comparative analysis of different approaches is carried out, which mathematically describes the metal droplet formation process in an electrode during gas metal arc (GMA) welding. It was shown that a hydrostatical model of the droplet's free surface could not correctly describe the formation and transfer of electrode metal droplets. The complete hydrodynamic model, which uses the whole system of Navier–Stokes equations, requires significant computer resources for numerical realization. This limits its application to small computational experiments. As an alternative for this model, the approximate hydrodynamic model adapted to GMA welding conditions is considered. It is shown that this model allows the prediction of droplet geometry right up to its detachment. The influence of the welding current and magnetic pressure on the droplet size and detachment frequency is studied.