Modelling of the arc in electric arc welding is significant to achieve a better process understanding, thus gain better weld quality and a more efficient production process. It requires knowing the conditions at the surfaces of the anode and cathode. These conditions are very difficult to set from measurements and should be calculated. This requires modelling the complex physics of the electrode layer coupling electrode and arc. This paper presents a self-consistent electrode layer model that 1) is suited to welding applications, 2) accounts for the known physics taking place, and 3) satisfies the basic conservation requirements. The model is tested for different conditions. Its potentiality for welding applications is shown through calculations coupling plasma arc, electrode and cathode layer models. The calculations are done for both tungsten and thoriated tungsten electrode.

thermal plasma, arc welding, electrode layer, sheath, electrode surface temperature, numerical simulation, OpenFOAM