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<p>Submerged arc welding (SAW) with multiple wires is used in pipe mills due to high deposition rates. The finite element method has been used previously for thermal modeling of multi-wire SAW. However, these calculations are time-consuming, making them impractical for shop floor applications. This study introduces a novel semi-analytical thermal model for multi-wire SAW, which reduces the computational time from several hours to approximately 4&#xa0;min when run in GPU using CUDA implementation. The proposed model assumes a superposition of a series of semi-ellipsoidal heat sources and uses the Green function approximation leading to a simplified expression. Experimental validation for a tandem SAW demonstrated an average error of 8% and 2% for melt pool width and depth, respectively. Thus, the developed model can be used for quick shop floor estimations.</p>

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Semi-analytical Thermal Model for Multi-wire Submerged Arc Welding

  • 期刊论文

  • 发表日期：

    2025年5月21日

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  • Y. Priyanka,
  • V. S. Hariharan,
  • J. L. Manikandan,
  • Adapa Mahanth Kumar,
  • Niyanth Sridharan,
  • Badri Narayanan,
  • Degala Venkata Kiran,
  • P. Mariappan

摘要

Submerged arc welding (SAW) with multiple wires is used in pipe mills due to high deposition rates. The finite element method has been used previously for thermal modeling of multi-wire SAW. However, these calculations are time-consuming, making them impractical for shop floor applications. This study introduces a novel semi-analytical thermal model for multi-wire SAW, which reduces the computational time from several hours to approximately 4 min when run in GPU using CUDA implementation. The proposed model assumes a superposition of a series of semi-ellipsoidal heat sources and uses the Green function approximation leading to a simplified expression. Experimental validation for a tandem SAW demonstrated an average error of 8% and 2% for melt pool width and depth, respectively. Thus, the developed model can be used for quick shop floor estimations.