Abstract: Considering the main characteristics of metal transfer in GMAW, a mathematical model for metal transfer is developed based on the “mass-spring” theory. Dynamic analysis of metal transfer in GMAW process is conducted. The effects of transfer mode and oscillation velocity on metal transfer behaviors are quantitatively analyzed. The detached droplet size and transfer frequency are predicted under different levels of welding current. It is found that under the condition of the same welding current the detachment of a molten droplet has a marked effect on the oscillation of successive droplet at the end of wire, the droplet size and transfer frequency. The predicted droplet size and transfer frequency are in agreement with the experimental results.

Key words: GMAW, Metal transfer, Numerical analysis