Thermal Modeling and Performance Evaluation of Electric Arc Welding Processes

Abstract

Electric arc welding (EAW) is a critical fabrication process used in numerous industries, including automotive, aerospace, construction, and shipbuilding. Its effectiveness hinges upon the accurate control of thermal inputs, which directly influence weld quality, material microstructure, and residual stress profiles. This study presents a detailed thermal modeling approach to simulate the transient heat distribution during EAW and evaluates the corresponding performance characteristics using both numerical and experimental methods. A three-dimensional finite element model (FEM) was developed using ANSYS to simulate the thermal cycle of a gas metal arc welding (GMAW) process applied to mild steel plates. The model incorporated Gaussian heat source distribution and temperature-dependent material properties. Thermal boundary conditions included convective and radiative heat losses to mimic realistic welding environments. The model was validated through thermocouple-based temperature measurements and metallurgical examination of welded specimens. Key performance parameters such as cooling rate, peak temperature, heat-affected zone (HAZ) dimensions, and weld bead geometry were extracted and compared with experimental data. The simulation results showed a strong correlation with measured values, with maximum error margins within ±10%. Parametric studies demonstrated that increasing welding current and decreasing travel speed significantly elevated peak temperatures and expanded the HAZ, affecting metallurgical properties. This study concludes that thermal modeling is a valuable tool for predicting weld outcomes, optimizing process parameters, and minimizing material degradation. The integration of computational simulation with experimental validation enhances process understanding, reduces trial-and-error in industrial settings, and facilitates the development of predictive welding quality control systems.