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Comparative Analysis of Models of Dynamic Welding Arc

Article · December 2015

DOI: 10.15407/tpwj2015.12.09

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 COMPARATIVE ANALYSIS OF MODELS
OF DYNAMIC WELDING ARC*
I.V. PENTEGOV and V.N. SYDORETS
E.O. Paton Electric Welding Institute, NASU
11 Bozhenko Str., 03680, Kiev, Ukraine. E-mail: office@paton.kiev.ua

K e y w o r d s : gas-shielded arc welding using consum- where Ucol is the function defining static volt-
able and non-consumable electrode, dynamic arc, mathe-
matical model, power balance, investigations
ampere characteristic (SVAC) of the arc column.
Input power is determined by arc column re-
There are number of dynamic arc models at pre- sistance as well as value of its transitional cur-
sent time. Therefore, the researchers when solv- rent:
ing the specific tasks on investigation of processes U col (iθ) 2
in power source—welding arc system face with P = R st(iθ)i2 = i . (4)
iθ
the problem of selection of a model providing
complete description of the main arc peculiarities Voltage on the arc column in dynamic is found
in each specific case. This paper is dedicated to from expression
objective estimation and comparison of models
of dynamic arc and elaboration of recommenda- U col (iθ)
ucol = i. (5)
tions for model selection on this basis. iθ
Some progress in description of welding arc
of constant length (non-consumable electrode) State current iθ for any representative point
as part of electric circuit was achieved using on plane, corresponding to arc column dynamic
mathematical model of dynamic arc, developed states in the coordinates of arc column voltage
at the E.O. Paton Electric Welding Institute arc current (ucol, i), is determined as x-coordinate
(PWI-MA) [1]. PWI-MA was further developed of cross point of beam from the origin, passing
in works [2, 3]. Arc column in PWI-MA has been through this point, with arc column SVAC. Work
phenomenological considered as heat inertial [3] shows that PWI-MA equation in differential
macroobject, for which the following power bal- form [2] corresponds to energy balance equation
ance is valid: (1):
dQ
= P — Pθ, (1) di2θ
dt θ = i2 — i2θ, (6)
dt
where Q is the internal energy of arc column; P
and Pθ is the input and output power, respec- which is electroengineering analog of equation
tively. All isoenergetic identical states in PWI- (1). At that internal energy of arc column equals
MA are characterized by one parameter, i.e. arc [3]
state current iθ [1, 3]. It determines such char-
iθ
acteristics of the arc column as static resistance
U col (iθ)
Q = 2θ ∫ Ucol (iθ)di θ, (7)
R st (iθ) = (2) 0
iθ
where θ is the time constant of arc column.
and output power Since all other models use such a value as arc
P θ = U col (iθ)iθ, (3) column conductivity g [4], PWI-MA equation

*
Translation of paper from «Avtomaticheskaya Svarka» Journal, 1989, No. 2, pp. 33—36. Monitoring of references to the papers, published
in this Journal, showed that paper of I.V. Pentegov and V.N. Sydorets is one of the most cited in area of welding arc modelling. It is
dedicated to comparison of dynamic model of arc, being developed at the E.O. Paton Electric Welding Institute, with other models and
is still of high interest up to the present moment. Unfortunately, «Avtomaticheskaya Svarka» Journal was not translated in English in
1989. However, current reality of the world scientific community necessitates publications in English. Therefore, the Editorial Board
of the Journal has made a decision to publish this paper in «The Paton Welding Journal» in order to make it more accessible to wider
audience of researchers, post-graduate students and students.

© I.V. PENTEGOV and V.N. SYDORETS, 2015

12/2015 45
(7) is transferred in conductivity terms using in equation (9) is the constant.
formula (2), from which Obviously, for this it is necessary that
iθ g iθ dU col
g= . (8) = = n = const.
U col (iθ) G dif (g) U col (iθ) diθ

PWI-MA equation is converted in g-form by Separating the variables and integrating the
differentiation of expression (8) by time and sub- latter equation the following is received:
stituting found diθ/dt value in equation (6): ⎛ i ⎞n
⎜ θ⎟ (15)
⎡ ⎤ 1 dg U col (iθ) = U 0 ⎜ ⎟ ,
2θ i2 i2 ⎜ I0 ⎟
⎢ ⎥ +1= 2 2 = , (9) ⎝ ⎠
⎢ g ⎥ g dt g U col (g) gP θ
⎢1 — ⎥ where U0 and I0 are the coordinates of one of
⎣ G dif (g) ⎦
SVAC fixed points.
where Gdif = (dUcol/diθ)—1 is the differential Thus, Cassies’s, Mayr’s and Zarudi’s models
conductivity. For making a comparison let us follow from PWI-MA (9) in a special case, when
provide equations of arc column dynamic of all SVAC has power form with index of power n,
widespread models. and equation (9) is written as
Cassie’s model [5]: 2
⎛ n ⎞1 — n
2θ 1 dg ⎜ I0 ⎟ i2
θC dg ⎛ i ⎞2 +1=⎜ ⎟ 2 .
+1=⎜ ⎟ , (10) 1 — n g dt ⎜ U0 ⎟
⎝ ⎠ 1—n
g dt ⎝ g UC ⎠ g

where θC is the arc time constant in Cassie’s Cassie’s model (10) is received at n = 0. Then
model; UC is the static voltage on the arc column, UC = U0 and θC = 2θ. Mayr’s model (11) takes
which is constant in Cassie’s model. place at n = —1. In this case PM = U0I0 and θM =
Mayr’s model [6]: = θ. Zarudi’s model (12) is realized at n = —(1 —
— k)/(1 + k). Then
θM dg i2
+1= , (11) ⎛ U ⎞1 + k
g dt gP M ⎜ 0⎟ 2θ
Xk = I20 ⎜ ⎟ and θZ = (1 + k)θ = .
⎜ I0 ⎟ 1—n
where θM is the time constant in Mayr’s model; ⎝ ⎠
PM is the output power, which is constant in Schellhase’s model (13) can not be received
Mayr’s model. from PWI-MA (9) under any conditions. It can
Zarudi’s model [7, 8]: be superposed neither with Cassie’s models no
with Zarudi’s model. Obviously, it is explained
θZ dg i2 by the fact that Schellhase’s model [9] was built
+1= k+1
, (12)
g dt g Xk on concepts, which did not use power balance
equation (1).
where θZ = (1 + k)θ is the value, which can be Specific attention is to be given to interpre-
considered as time constant in Zarudi’s model; k tation of coefficient τ from formula (14). It was
is the index of plasma non-linearity depending mentioned above that this coefficient remains
on gas nature, in which arc burns; Xk is the con- constant in the case of SVAC power function
stant at fixed k. (15). Therefore, it is called an arc time constant
Schellhase’s model [9]: in different models. In general case τ value de-
pends on conductivity and can not be interpreted
θS dg 1 as arc time constant. Moreover, as it is shown in
+1= , (13)
g dt gU col (i) work [3], the transfer processes in the circuit
with arc generally can not be characterized by
where θS is the time constant in Schellhase’s
process time constant. This conclusion matches
model.
with the results of experimental investigations
Comparison of the models show that the time
in works [10, 11]. Thus, PWI-MA eliminates
constants are different in all models. Let us con- existing contradiction on variability of arc time
sider what are the conditions when expression constant. The arc time constant θ in PWI-MA is
2θ the invariable value, but it is not time constant
τ= (14) of the process. And generally coefficient τ is the
g
1— variable value.
G dif (g)

46 12/2015
 It follows from mentioned above that PWI- di 2θ ⎛ vl Q ⎞⎟
⎜ (20)
MA applicable to welding arc has series of ad- θ = i2 — i2θ ⎜1 + ⎟
dt ⎜ la P θ ⎟
vantages in comparison with other methods. ⎝ ⎠
PWI-MA is the most general of all models. It and for particular case of power approximation
can use SVAC of any type (including areas with of SVAC curve (15)
independent and growing SVAC), that is very
di 2θ ⎛ 2θvl ⎞⎟
important in welding arc modelling. PWI-MA, ⎜ (21)
θ = i2 — i2θ ⎜1 + ⎟.
in terms of electric engineering, uses a value of dt ⎜ (1 + n)la ⎟
⎝ ⎠
state current, that has apparent advantages in
comparison with other models, which use values In the latter formula n ≠ 1 since SVAC can
of conductivity or arc column resistance. PWI- not be hyperbola at all integration interval [3]
MA allows easily determining such important due to inversion into infinity of value of arc in-
energy parameters of the arc column as output ternal energy Q. Generally, SVAC is not approxi-
power and internal energy of the arc column. mated by power function, and it is necessary to
Formula (7) for internal energy of the arc col- use common equation (19). Expression in square
umn, obtained with the help of PWI-MA, allows brackets is easily calculated at any form of arc
expanding sphere of application of dynamic arc SVAC.
equations, including for the cases of arcs with Obtained equation reveals more perspectives
varying in time arc length la(t) as well as moving in solving the problems relating with consumable
and blown arcs, that is in principle inaccessible electrode welding, since this method of welding
for alternative arc models. is the most widespread.
Using equality Gas blowing of welding arc provides for ad-
ditional mechanism of energy output, power of
U col (iθ) = la(t)E col (iθ), (16) which at longitudinal blowing
where Ecol(iθ) is the average value of electric Vsp |vbl|
Pv = Q= Q, (22)
field intensity in the arc column (SVAC of the Va la
arc is determined particularly for this value of
intensity, in the case of cylindrical arc, Ecol(iθ) at transverse blowing
agrees with real electric field intensity in the arc Vsp 2le|vbl |
column). Let us transfer equation (7) in the fol- Pv = Q= Q, (23)
Va πlara
lowing form:
iθ (i) where Vsp is the volume of plasma being blown
per unit of time.
Q = 2θla(t) ∫ Ecol (iθ)diθ. (17)
For longitudinal blowing
0
V sp = πr2a|vbl |,
Here out
for transverse blowing
dQ ∂Q di θ ∂Q dla
= + =
dt ∂iθ dt ∂la dt V sp = 2rale|vbl |.
iθ
(18)
dt θ
Here vbl is the blowing rate; ra is the arc col-
dla
= 2θlaE col (iθ)
dt
+ 2θ
dt
∫ Ecol (iθ)diθ. umn radius; le is the distance between the elec-
0 trodes, in general case le ≤ la; Va is the arc volume.
Equation of power balance in this case has a
Substituting this expression together with (3) form of
and (4) in equation (1), PWI-MA equation for
changing arc length is received in general case: dQ
= P — Pθ — P v. (24)
dt
iθ
⎧ ⎡ ⎤⎫
⎪ ⎢ ⎥⎪ PWI-MA equation for longitudinal blow is
⎪ ⎢ ∫ E col(iθ)di θ ⎥⎪
2
di θ ⎨ 2θvl ⎢ ⎥⎬
θ 2 2 ⎪
= i — iθ ⎪ 1 + ⎢0 ⎥⎪ (19) di 2θ ⎛
⎜ |vbl | Q ⎞⎟
dt la ⎢ E (i )i ⎥⎪, θ = i2 — i2θ ⎜1 + ⎟,
(25)
⎩ ⎣ col θ θ ⎦⎭ dt ⎜ la P θ ⎟
⎝ ⎠
where vl = dla/dt is the rate of arc length change.
and for transverse blow
The latter equation assumes the following
di 2θ ⎛ ⎞
form of record for general case ⎜ 2 le |vbl | Q ⎟ (26)
θ = i2 — i2θ ⎜1 + π ⎟.
dt ⎜ la ra P θ ⎟
⎝ ⎠

12/2015 47
 Equation (25) is expedient to be used for de-
scription of processes with plasma arc applica-
tion, when longitudinal gas blow is inseparable
part of the process. Equation (26) shall be used
in transverse blowing as well as for different
cases of arc movement, including arc movement
in magnetic field, at that vbl is considered as arc
movement rate. It should be noted that different
combinations of equations (19), (24) and (25)
are possible. For example PWI-MA equation
di 2θ ⎛ |vbl | + vl Q ⎞⎟
⎜ (27)
θ = i2 — i2θ ⎜1 + ⎟ 5. Cassie, A.M. (1939) A new theory of arc rupture and
dt ⎜ la Pθ ⎟
⎝ ⎠
is valid in arc length change and longitudinal arc
blow.
Conclusions
1. Mathematical model of dynamic arc is valid
for any types of SVAC and allows solving the
problems in the electroengineering terms. It can
be used in the cases of varying length arcs (in-
cluding the consumable electrode arc), moving
arcs and gas blown arcs, and provides the method
for determination of internal energy and output
power, that is impossible in alternative models.
2. Obtained results are valid not only for weld-
ing, but for plasma arcs and rupturing arcs in
electric apparatuses.
3. Using the computer PWI-MA equations
allows investigating evolutionary processes in
power source—arc system for various cases of gas-
*Pentegov, I.V., Sidorets, V.N. (1990) Energy parameters in a mathematical model of a dynamic welding arc. Welding Int., 4 (4),
272—275.
48
shielded welding, namely consumable-electrode
in inert gases and mixture of active gases and
tungsten-electrode in inert gases welding.
1. Pentegov, I.V. (1976) Mathematical model of col-
umn of electric dynamic arc. Avtomatich. Svarka, 6,
8—12.
2. Pentegov, I.V., Sydorets, V.N., Genis, I.A. (1984)
Problems of modelling of welding arc dynamics as
part of electric circuit. Ibid., 10, 18—23.
3. Pentegov, I.V., Sydorets, V.N. (1988) Energy pa-
rameters in mathematical model of dynamic welding
arc. Ibid., 11, 36—40.*
4. Novikov, O.Ya. (1987) Electric arc stability. Lenin-
grad: Energiya.
circuit severity. CIGRE, 102, 1—10.
6. Mayr, O. (1943) Beitrage zur Theorie des statischen
und des dynamischen Lichtbogens. Arch. fuer
Elektr., 38, 588—608.
7. Zarudi, M.E. (1971) On effect of non-linear proper-
ties of plasma on character of non-stationary proc-
esses in column of channel arc (Problems of theory
and calculation). Zhurnal Tekhn. Fiziki, 41(4), 734—
743.
8. Zarudi, M.E. (1977) Criteria of existence and stabil-
ity of stationary modes in alternating current induc-
tive circuit with arc. Elektrichestvo, 4, 53—60.
9. Schellhase, M. (1971) Mathematical model of trans-
fer processes in welding arc and its investigations.
Avtomatich. Svarka, 7, 13—16.
10. Kruchinin, A.M., Peshekhonov, V.I., Lazutkin,
Yu.V. et. al. (1983) Calculation of arc time constant
on computer. In: Mathematical modelling and disign
of electric arc and plasma steel furnaces: Transact. of
VNIIETO, 46—49. Moscow: Energoatomizdat.
11. (1981) Current interruption in high-voltage mains.
Moscow: Energoizdat.
Received 04.11.2015
12/2015
 E.O. Paton Electric Welding Institute of the National Academy of Sciences of Ukraine

International Scientific-Technical and Production Journal

December 2015
No.12
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English translation of the monthly «Avtomaticheskaya Svarka» (Automatic Welding) journal published in Russian since 1948

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Editor-in-Chief B.E. Paton
Scientists of PWI, Kiev
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Yu.S. Borisov, G.M. Grigorenko,
SCIENTIFIC AND TECHNICAL
A.T. Zelnichenko, V.V. Knysh,
I.V. Krivtsun, Yu.N. Lankin, Paton B.E., Kaleko D.M., Kedrovsky S.N., Koval Yu.N.,
L.M. Lobanov, V.D. Poznyakov, Krivtsun I.V. and Slepchenko V.N. Resistance welding of
I.A. Ryabtsev, V.F. Khorunov,
shape-memory copper—aluminium alloy ......................................... 2
K.A. Yushchenko
Scientists of Ukrainian Universities
M.N. Brykov, ZNTSU, Zaporozhie Maksymova S.V., Khorunov V.F. and Myasoedov V.V.
V.V. Dmitrik, NTU «KhPI», Kharkov Effect of depressants and base metal on microstructure of
V.F. Kvasnitsky, NUS, Nikolaev brazed seams in joints of Ni3Al-based alloys with
V.D. Kuznetsov, NTUU «KPl», Kiev
Foreign Scientists
Inconel 718 alloy ........................................................................... 8
N.P. Alyoshin
N.E. Bauman MSTU, Moscow, Russia Khaskin V.Yu., Korzik V.N., Sydorets V.N., Bushma A.I.,
Guan Qiao Wu Boyi and Luo Ziyi. Improving the efficiency of hybrid
Beijing Aeronautical Institute, China
A.S. Zubchenko welding of aluminum alloys ........................................................... 14
DB «Gidropress», Podolsk, Russia
M. Zinigrad Tsybulkin G.A. On the influence of capacitance in the
College of Judea & Samaria, Ariel, Israel welding circuit on stability of arc welding mode ............................. 19
V.I. Lysak
Volgograd STU, Russia
Ya. Pilarczyk Dmitrik V.V., Sobol O.V., Pogrebnoj M.A., Glushko A.V.
Welding Institute, Gliwice, Poland and Ishchenko G.I. Structural changes in metal of welded
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Fax: (38044) 200 82 77, 200 81 45 Pentegov I.V. and Sydorets V.N. Comparative analysis of
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