A. Kumar, ExxonMobil Upstream Research Co., Houston, TX; T. DebRoy, The Pennsylvania State University, University Park, PA

Summary: Because of recent advances in computational hardware and software, it is now possible to construct a model that can provide window of welding parameters to achieve a target geometry based on scientific principles. Using the window of welding parameters obtained by the proposed model, the calculated shape and size of the fusion zone, finger penetration characteristic of the GMA welds and the solidified free surface profile were similar to those obtained from experiments under similar welding conditions. Good agreement between the model predictions and experiments show that this model empowers practicing engineers to determine a window of input variables that would lead to a target weld geometry.