Understanding of thermal behaviour in keyhole plasma arc welding process through numerical modelling–an overview

Numerical modelling techniques are usually employed in keyhole plasma arc welding (KPAW) process to comprehend the thermal analysis, effect of welding parameters, weld geometry and weld quality without physical experiments. The simulated results provide insights into various aspects of the process, thus reducing consumable costs and process time. Quality in KPAW mainly relies on thermal distribution during the progress of keyhole and weld pool. This review paper focuses on different heat source models and heat transfer models associated with the KPAW process, thus emphasizing the importance of compliance with keyhole generation and volumetric heat intensity distribution along the thickness of the base metal. The paper also covers the fundamental principles of heat transfer and thermo-physics involved in KPAW.