Three-dimensional simulation of the plasma arc welding process

A finite element-based simulation of the plasma arc welding process is presented. The simulation determines the weld pool's three-dimensional capillary surface shape, the approximate solid-liquid phase boundary, and calculates the pool's three-dimensional flow and temperature fields. The simulation is first used to examine the effect of ambient temperature and plate speed on pool shape. Pool flow is then studied. The flow's qualitative features are primarily determined by jet shear and thermocapillarity while buoyancy is of secondary importance.