Numerical simulation of dynamic development of keyhole in double-sided arc welding

Double-sided arc welding (DSAW) is a novel process for joining metals that is capable of achieving deep narrow penetration in a single pass with minimized distortion. A clear understanding of the process fundamentals is critical in order to fully examine the potential of DSAW, to guide the further developments of the process, to direct the practicability study, and to design the process parameters. This paper aims at developing a numerical model for examining and simulating the dynamic keyhole establishment process, which will be a key in developing an effective control technology for DSAW. The model is used to determine the geometrical shape of the keyhole and the weld pool, and the temperature distribution in the workpiece. Quantitative information on the establishment of the keyhole in DSAW, such as the transient development of the keyhole and the weld pool, the increase rate of the depth of the surface depression, the time interval from full penetration to the keyhole establishment, the minimum span of the weld pool for describing the conditions required to complete the keyhole establishment, and variation of the overflow height of the weld pool surface on the plasma arc welding side, has been obtained through numerical analysis. The DSAW experiments show that the predicted weld cross-section is in agreement with the measured one. The results lay a foundation for guiding the further development of the DSAW process and its effective control.