Stability of droplets in gas metal are welding

A method is developed to compute the stability of droplets detaching from t he consumable electrode in gas metal arc welding. An aluminium electrode is used as the model system. Theoretical predictions and supporting experimen ts are used to ascertain the rate of transfer of droplets for a range of cu rrent encompassing globular and spray transfer, and to examine the transiti on between these distinct modes of metal transfer. The method uses dimensio nal analysis to correlate the mass, rate of transfer, and force acting to d etach droplets. The correlation is found to undergo a notable change in slo pe at the transition between globular and spray transfer. The accuracy of t he correlation is assessed by comparing the theoretical and measured rate o f transfer of droplets in gas metal arc welding using aluminium electrodes of variable diameter.