The distribution of the heat content of filler metal droplets inside the gas—metal arc (GMA) weld pool has a marked effect on the weld bead dimensions and the weld thermal cycle. A model is developed to account for this distribution. Volumetric distribution of the heat content of droplets within the weld pool is considered as an internal heat generation term. Based on physical reality, an algorithm is proposed to determine the geometry and size of the volume within which the heat content of droplets is distributed. Bead-on-plate GMA welding experiments show that the predicted weld dimensions and temperature variations are in agreement with the measured values.
