Mathematical modeling of flux consumption during twin-wire welding

Mathematical models for flux consumption during twin-wire welding with direct current electrode positive and direct current electrode negative have been presented. The models illustrate the flux consumption in the form of a function relation between different process parameters. The present work is the result of a large number of experimental observations, modelling, and subsequent validation. The accuracy and predictability along with the use of shop-floor controllable parameters as model inputs make the proposed models useful for industrial application. The effects of process parameters have been further analyzed. The analysis revels that current, voltage, wire diameters and polarity are the major factors influencing the flux consumption during the twin wire welding, while welding speed and contact-tube-to-work-piece-distance are found to be significant with electrode negative. One of the important observations during the present investigation is regarding influence of dissimilar wire diameters at the lead and trail wires on the flux consumption. Mathematical analysis of magnetic field generated in the vicinity of the arc, particularly with dissimilar diameter, affects the arc deflection and affects the flux consumption.