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<p>Slag viscosity plays a crucial role in governing heat and mass transfer in submerged arc welding (SAW), directly shaping the weld pool characteristics. The effects of different slag viscosities vary significantly, making it a critical consideration in optimizing flux design. To quantify pertinent effects, a three-dimensional transient computational fluid dynamics (CFD) weld pool model has been developed, employing slag viscosity as the sole variable for numerical analysis. Obtained results indicate that the significant decrease in the spreading ability of molten metal on the weld pool surface occurs primarily within the lower viscosity range. As the slag viscosity increases from 50 to 100 mPa s, the maximum width of the weld pool decreases significantly from 21.82 to 19.02 mm, while the Reynolds number decreases, indicating a transition from inertia-dominated to viscosity-dominated flow. The internal convection within this range is also significantly enhanced, leading to deeper penetration, with the maximum weld penetration increasing from 7.49 to 8.01 mm. However, when the slag viscosity exceeds 200 mPa&#xa0;s, the trend of decreasing weld pool width slows down, and the maximum weld penetration reaches a steady state. Such findings may offer new insights toward fine-tuning the optimal slag viscosity range for SAW.</p>

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Identifying the Role of Slag Viscosity Upon Submerged Arc Weld Pool Features: A Computational Fluid Dynamics Investigation

  • 期刊论文

  • 发表日期：

    2025年6月4日

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  • Hangyu Bai,
  • Yanyun Zhang,
  • Hang Yuan,
  • Cong Wang

摘要

Slag viscosity plays a crucial role in governing heat and mass transfer in submerged arc welding (SAW), directly shaping the weld pool characteristics. The effects of different slag viscosities vary significantly, making it a critical consideration in optimizing flux design. To quantify pertinent effects, a three-dimensional transient computational fluid dynamics (CFD) weld pool model has been developed, employing slag viscosity as the sole variable for numerical analysis. Obtained results indicate that the significant decrease in the spreading ability of molten metal on the weld pool surface occurs primarily within the lower viscosity range. As the slag viscosity increases from 50 to 100 mPa s, the maximum width of the weld pool decreases significantly from 21.82 to 19.02 mm, while the Reynolds number decreases, indicating a transition from inertia-dominated to viscosity-dominated flow. The internal convection within this range is also significantly enhanced, leading to deeper penetration, with the maximum weld penetration increasing from 7.49 to 8.01 mm. However, when the slag viscosity exceeds 200 mPa s, the trend of decreasing weld pool width slows down, and the maximum weld penetration reaches a steady state. Such findings may offer new insights toward fine-tuning the optimal slag viscosity range for SAW.