Study of the Sensitivity of DC Arc Temperature Field, Pressure Field, and Potential to Process Parameters

DC arcs are widely used in many fields such as shipbuilding, machinery manufacturing, and aerospace due to their advantages of high energy density, simple structure, and low price. However, there are few studies on the sensitivity of the arc pressure and temperature fields to current and protective gas flow rate. In order to solve this problem, this paper establishes a numerical model for the coupling of DC arc electric–thermal–flow multi-physical fields. Based on this model, the variation rules of the arc temperature, pressure, and potential field with current or protective gas flow rate are studied, respectively, when the current is 100–600 A or the gas flow rate is 18–48 L/min. The results show that the current is the most important factor in the sensitivity of the arc temperature and potential field to the current and protective gas flow rate. With the increase in current, the Joule heat power increases significantly, and the arc central temperature shows a nonlinear increase to 27,000 K. With increasing current, the peak of the pressure field gradually shifts to the region below the top of the wire arc, and the highest pressure increases by 14 times. When the current is small, the increase in argon flow rate can inhibit the spreading of the temperature field by forced convection; when the current is large, the arc contraction with an increasing argon flow rate leads to an anomalous increase in the arc-central temperature. In addition, the energy accumulation mechanism in the strong-current–high-flow-rate coupling region is also revealed, a coupled mathematical model of arc contraction and turbulent loss under the Lorentz force is constructed, and the thermodynamic properties of the arc under the coupling of multi-physical fields are elucidated.