The composition, size distribution, and number density-of oxide inclusions
in weld metal are critical factors in determining weldment properties. A co
mputational model has been developed to understand these factors, consideri
ng fluid flow and the temperature field in the weld pool during submerged a
re (SA) welding of low-alloy steels. The equations of conservation of mass,
momentum, and energy are solved in three dimensions to calculate the veloc
ity and temperature fields in the weld pool. The loci and corresponding the
rmal cycles of thousands of pride inclusions are numerically calculated in
the weld pool. The inclusions undergo considerable recirculatory motion and
experience strong temperature gyrations. The temperature-time history and
the computed time-temperature-transformation (TTT) behavior of inclusions w
ere then used to understand the growth and dissolution of oxide inclusions
in the weld pool. The statistically meaningful characteristics of inclusion
behavior in the weld pool, such as the residence time, number of temperatu
re peaks, etc., were calculated for several thousand inclusions. The calcul
ated trends agree with experimental observations and indicate that the incl
usion formation can be described by combining thermodynamics and kinetics w
ith the fundamentals of transport phenomena.