A three dimensional model with a moving heat source is developed to de
scribe heat transfer and fluid flow in transient weld pools. Full pene
tration and free top and bottom surfaces are incorporated in the model
in order to simulate the welding process more practically. The influe
nce of plate thickness and welding current on the dynamics of weld poo
ls is analyzed using calculated data. It is shown that when the workpi
ece is nearly penetrated, the depth of weld pool increases quickly. Al
so, the elevation of the top surface decreases quickly once the full p
enetration status is established.