A Comparative Analysis of the Weld Pools Created with DC Single-, DC Double-, and PC Double-Electrode Configurations in Autogenous GTAW

Three different Gas Tungsten Arc Welding methods—DC single electrode, DC double electrode, and PC double electrode—were analyzed using SS304 steel as the base material. Numerical models were developed to simulate the arc plasmas and calculate heat flux, current density, and wall shear stress on the surface of the workpiece. These data were used as input to simulate the weld pools across all three configurations. Experimental validation showed a good agreement with the numerical results. In the double-electrode setup, electromagnetic interaction caused the arcs to deflect, resulting in an 8% reduction in the maximum heat flux and a 4% decrease in the maximum current density. Marangoni stress had a notable effect on the weld pool shape, creating a -shaped pool with the stationary single-electrode setup, whereas the double-electrode setup produced a -shaped pool after 2 s. In the moving weld pool configurations, the sizes of the pools were maximum at the trailing electrodes. The pool was 1.7 mm deep and 5.6 mm wide in DC double- and 1.4 mm deep and 5.4 mm wide in PC double-electrode configurations. The pool depth and width were only 1.0 mm and 4.2 mm when a DC single-electrode setup was used. Comparing the three methods, the DC double-electrode setup produced the largest pool size. The findings of this research offer guidance for enhancing different arc settings and electrode arrangements to attain the intended welding quality and performance.