Numerical analysis arc behavior in single-power double-wire single-arc gas metal arc welding

• Reduce key arc plasma parameters by over 36% compared to single-wire GMAW at 300 A. • Reduced arc intensity leads to shallower penetration and a wider weld width. • The quantified coupling of these factors determines the penetration depth and width. The understanding of arc behavior remains critically important for advancing welding technologies. This study investigates the arc behavior of a single-power double-wire single-arc (SDS) gas metal arc welding (GMAW) platform through numerical modeling and comparative analysis with traditional single-wire GMAW (S-GMAW). A finite element model is developed to analyze the effects of double-wire spacing on arc characteristics, including temperature, current density, pressure, and plasma velocity distributions. At a welding current of 300 A, SDS-GMAW with spacing exhibits significantly lower values compared to both SDS-GMAW without spacing and S-GMAW. Specifically, the maximum arc temperatures for SDS-GMAW with spacing, SDS-GMAW without spacing, and S-GMAW are 18,222.4 K, 18,923.4 K, and 28,619.5 K, respectively, showing reductions of 36.3% and 33.9% for SDS-GMAW with spacing, SDS-GMAW without spacing relative to S-GMAW. Similarly, the maximum current densities (5.77 × 10⁷, 5.89 × 10⁷, and 1.50 × 10⁸ A/m²), arc pressures (231.9 Pa, 310.9 Pa, 964.8 Pa), and z-direction plasma velocities (106.4 m/s, 174.2 m/s, 450.5 m/s) follow the same trend, with SDS-GMAW with spacing achieving reductions of 61.5%, 75.9%, and 76.4% in current density, pressure, and velocity, respectively, compared to S-GMAW. These reductions correlate with observed weld morphology: SDS-GMAW with spacing produces shallower penetration and wider weld widths compared to the unspaced configuration, while S-GMAW yields the deepest penetration. The results demonstrate that weld geometry is governed by synergistic interactions among arc temperature, current density, pressure, and plasma velocity. This study provides quantitative insights into arc behavior modulation through dual-wire configurations, offering a foundation for optimizing welding processes in industrial applications.