Numerical simulation of arc, metal transfer and its impingement on weld pool in variable polarity gas metal arc welding

2021 ◽  
Vol 64 ◽  
pp. 1529-1543
Author(s):  
Adeel Ikram ◽  
Hyun Chung
Keyword(s):  
Numerical Simulation ◽  
Weld Pool ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Metal Transfer ◽  
Metal Arc Welding ◽  
Variable Polarity

Erratum to: Mechanisms of weld pool flow and slag formation location in cold metal transfer (CMT) gas metal arc welding (GMAW)

2017 ◽  
Vol 61 (6) ◽  
pp. 1287-1287 ◽  
Author(s):  
Md. R. U. Ahsan ◽  
Muralimohan Cheepu ◽  
Rouholah Ashiri ◽  
Tae-Hoon Kim ◽  
Chanyoung Jeong ◽  
...  
Keyword(s):  
Weld Pool ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Metal Transfer ◽  
Slag Formation ◽  
Cold Metal Transfer ◽  
Metal Arc Welding ◽  
Cold Metal

Effects of Welding Current on Metal Transfer and Weld Pool Dynamics in Gas Metal Arc Welding

2006 ◽  
Author(s):  
J. Hu ◽  
H. L. Tsai ◽  
P. C. Wang
Keyword(s):  
Weld Pool ◽  
Arc Welding ◽  
Gma Welding ◽  
Gas Metal Arc Welding ◽  
Metal Transfer ◽  
Dominant Factor ◽  
Transient Temperature ◽  
Transfer Mode ◽  
Metal Arc Welding ◽  
Metal Transfer Mode

In gas metal arc welding (GMAW), current is one of the most important factors affecting the mode of metal transfer and subsequently the weld quality. Recently, a new technology using pulsed currents has been employed to achieve the one droplet per pulse (ODPP) metal transfer mode with the advantages of low average currents, a stable and controllable droplet generation, and reduced spatter. In this paper, the comprehensive model recently developed by the authors was used to study the influences of different current profiles on the droplet formation, metal transfer, and weld pool dynamics in GMA, welding. Five types of welding currents were studied, including two constant currents and three waveform currents. In each type, the transient temperature and velocity distributions of the arc plasma and the molten metal, and the shapes of the droplet and the weld pool were calculated. The results showed that a higher electromagnetic force was generated at a higher current and becomes the dominant factor that detaches the droplet from the electrode tip. A smaller droplet size and a higher droplet frequency were obtained for a higher current. The model has demonstrated that a stable ODPP metal transfer mode can be achieved by choosing a current with proper waveform for given welding conditions.

Mechanisms of weld pool flow and slag formation location in cold metal transfer (CMT) gas metal arc welding (GMAW)

2017 ◽  
Vol 61 (6) ◽  
pp. 1275-1285 ◽  
Author(s):  
Md. R . U. Ahsan ◽  
Muralimohan Cheepu ◽  
Rouholah Ashiri ◽  
Tae-Hoon Kim ◽  
Chanyoung Jeong ◽  
...  
Keyword(s):  
Weld Pool ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Metal Transfer ◽  
Slag Formation ◽  
Cold Metal Transfer ◽  
Metal Arc Welding ◽  
Cold Metal

Mechanically assisted droplet transfer process in gas metal arc welding

2002 ◽  
Vol 216 (4) ◽  
pp. 555-564 ◽  
Author(s):  
Y Wu ◽  
R Kovacevic
Keyword(s):  
Transfer Process ◽  
Arc Welding ◽  
High Speed ◽  
Gas Metal Arc Welding ◽  
Metal Transfer ◽  
Droplet Transfer ◽  
Macroscopic Appearance ◽  
Transfer Mode ◽  
Metal Arc Welding ◽  
Separate Control

Gas metal arc welding has been generally accepted as the preferred joining technique due to its advantages in high production and automated welding applications. Separate control of arc energy and arc force is an essential way to improve the welding quality and to obtain the projected metal transfer mode. One of the most effective methods for obtaining separate control is to exert an additional force on the metal transfer process. In this paper, the droplet transfer process with additional mechanical force is studied. The welding system is composed of an oscillating wire feeder. The images of molten metal droplets are captured by a high-speed digital camera, and both the macroscopic appearance and the cross-sectional profiles of the weld beads are analysed. It is shown that the droplet transfer process can be significantly improved by wire electrode oscillation, and a projected spray transfer mode can be established at much lower currents. By increasing the oscillation frequency, the droplet transfer rate increases while the droplet size decreases. In addition, the improvement in the droplet transfer process with wire oscillation leads to an enhancement of the surface quality and a modification of the geometry of the weld beads that could be of importance for overlay cladding and rapid prototyping based on deposition by welding.

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