Influences of deposited metal material parameters on weld pool geometry during shield metal arc welding

Weld pool geometry performs an important function in improving weld quality during welding. In the present work, the influences of deposited metal material parameters, including surface tension gradient, magnetic permittivity, and thermal expansion coefficient, on weld pool geometry were investigated. Fusion length (FL) and fusion ratio (FR) were proposed to analyze weld pool evolution quantitatively. Results reveal that surface tension gradient exerts the most significant effects on weld pool geometry. The effects of magnetic permittivity are less extensive than those of surface tension gradient, and thermal expansion coefficient exerts only slight influences on weld pool geometry. Considering the effects of surface tension gradient, magnetic permittivity, and thermal expansion coefficient, a classification method for deposited metals was proposed. Based on the characteristics of the weld pool geometry, heat and mass transfer processes in the weld pool, and application conditions, various types of deposited metals were analyzed. Comparison of the simulated and experimental results showed that the error ranges of FR and FL are 3.66-4.53% and 1.03-2.83%, respectively.