A 3D mathematical model is developed to calculate the temperature and velocity distributions in a moving gas tungsten arc (GTA) welding pool with different sulfur concentrations. It has been shown that, the weld penetration increases sharply with increasing sulfur content. When sulfur content increases beyond 80×10-6, the increase in sulfur content does not have an appreciable difference on the welding pool size and shape, and the depth/width remains constant. Sulfur changes the temperature dependence of surface tension coefficient from a negative value to a positive value and causes significant changes on flow patterns. The increase in soluble sulfur content and the decrease at free surface temperature can extend the region of positive surface tension coefficient. As sulfur content exceeds 125×10-6, the sign of surface tension coefficient is positive. Depending upon the sulfur concentrations, three, one or two vortexes that have different positions, strength and directions may be found in the welding pool. The contrary vortexes can efficiently transfer the thermal energy from the arc, creating a deep welding pool. An optimum range of sulfur content is 20~150×10-6.
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