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<p>Tungsten inert gas (TIG) welding is recognized as a high-quality, versatile, and cost-effective welding method. However, the occurrence of humping defects significantly restricts its progression toward higher efficiency. This study investigates the impact of surface tension variations on the formation of humping defects in stainless steel high-speed TIG welding. Through a combination of numerical simulations and experimental comparisons, the study reveals the formation mechanisms of several typical humping weld profiles. The results indicate that the interplay between surface tension and molten pool temperature is a critical factor influencing the occurrence of humping defects. In the thin layer of the weld pool, the backflow of molten metal is obstructed, forming a “stagnation zone.” Here, the liquid metal solidifies prematurely, dividing the weld pool and contributing to humping formation. Variations in weld pool flow dynamics, influenced by surface tension, are the primary reason for different humping morphologies. Adjusting the surface tension state of the molten pool can effectively suppress humping defects, alter the molten pool morphology, and enhance welding efficiency without additional heat input.</p>

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Forming mechanism of humping defects in stainless steel high-speed TIG welding

  • 期刊论文

  • 发表日期：

    2025年4月9日

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  • Siyu Zhang,
  • Honglei Zhao,
  • Yiwen Li,
  • Junyan Miao,
  • Yuze Liu,
  • Yunlong Chang

摘要

Tungsten inert gas (TIG) welding is recognized as a high-quality, versatile, and cost-effective welding method. However, the occurrence of humping defects significantly restricts its progression toward higher efficiency. This study investigates the impact of surface tension variations on the formation of humping defects in stainless steel high-speed TIG welding. Through a combination of numerical simulations and experimental comparisons, the study reveals the formation mechanisms of several typical humping weld profiles. The results indicate that the interplay between surface tension and molten pool temperature is a critical factor influencing the occurrence of humping defects. In the thin layer of the weld pool, the backflow of molten metal is obstructed, forming a “stagnation zone.” Here, the liquid metal solidifies prematurely, dividing the weld pool and contributing to humping formation. Variations in weld pool flow dynamics, influenced by surface tension, are the primary reason for different humping morphologies. Adjusting the surface tension state of the molten pool can effectively suppress humping defects, alter the molten pool morphology, and enhance welding efficiency without additional heat input.