Modeling and Simulation of Weld Wire Melting and Droplet Transition Process in Wire Arc Additive Manufacturing
Based on the dynamic mesh and multi-physics field coupling techniques,a numerical model of heat-fluid coupling for welding wire melting and melt droplet transition was established.The melting processes of the wire to form a droplet,contact and spreading of the droplet with the substrate,as well as the formation of a molten metal bridge and the pull-off process were investigated.The temperature variation of the molten droplet during wire feeding,the velocity variation of the droplets and the melt pool,and the volume change of the molten droplets during mass transfer were analyzed.The size and shape of the molten droplet were in good agreement with the experimental results.The volume of molten aluminum finally transferred to the substrate surface was about 80%of the total volume of the molten droplet.
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