Numerical analysis of temperature field during double-sided arc welding of thick materials

Double-sided arc welding (DSAW) is a novel arc process developed at the University of Kentucky in which the workpiece is disconnected from the power supply and the two torches are used to establish two arcs on the both sides of the workpiece to close the current loop. As a result, the welding current is forced to flow through the workpiece along the thickness direction. This configuration and current flow direction improve the concentration of the arc energy distribution and provide a mechanism to guide the arc into the keyhole. Hence, DSAW process is capable of achieving deep narrow penetration and symmetrical welds. However, despite the progress in process development, there is a lack of a clear understanding of the physical processes and phenomena occurring in the weldment. In this study, a numerical model is developed to compute the temperature field and history in double-sided arc weldment. Using this numerical model, the temperature distributions and profiles at different cross-sections and along different lines of interest have been computed and compared with the results in regular plasma arc welding. It was found that DSAW process has advantages in obtaining deep narrow penetration, in producing symmetrical hour glass-shaped welds, in reducing the sensitization zone, in lowering the temperature gradient along the thickness, thus lowering the thermal distortion and residual stress, and in decreasing the sensitization duration.