scholarly journals Single-Pass Cladding Process Using Hot-wire Gas Metal Arc Welding Technique

2019 ◽  
Vol 269 ◽  
pp. 01006
Author(s):  
Pattanawit Suntiniwat ◽  
Eakkachai Warinsiriruk ◽  
Sutep Joy-A-Ka
Keyword(s):  
Stainless Steel ◽  
Gas Metal Arc Welding ◽  
Ccd Camera ◽  
Travel Speed ◽  
Hot Wire ◽  
Single Pass ◽  
High Production Rate ◽  
Feeding Speed ◽  
Wire Feeding ◽  
Wire Filler

The aim of this study is to improve cladding process productivity by high production rate with low dilution process by specifying technique as hot-wire GMAW process. The base metal of carbon steel A516 Gr70 was cladded by austenitic stainless steel 309LSi for creating a buttering layer and stainless steel 308LSi for hot-wire filler for topping a cladding layer in a one-pass run. The studied parameters this experiment consist of the feeding ratio of hot wire feeding speed per GMAW wire feeding speed and travel speed. Welding phenomenon during welding was observed by CCD camera with specifying the optical device to see the appropriate condition. The result showed the hot-wire GMAW cladding process could reduce cycle time 3.5 times compare with conventional FCAW cladding process. Moreover, dilution of this process could decrease lower than 15% with acceptable FN 3 on the top of weld surface. Therefore, single pass cladding process achieved by using this method with low dilution by still keep microstructure capability.

Comparison of Hardness and Microstructures Produced Using GMAW and Hot-Wire TIG Mechanized Welding of High Strength Steels

2014 ◽  
Author(s):  
A. R. H. Midawi ◽  
E. B. F. Santos ◽  
A. P. Gerlich ◽  
R. Pistor ◽  
M. Haghshenas
Keyword(s):  
Weld Metal ◽  
Deposition Rate ◽  
Heat Input ◽  
Gas Metal Arc Welding ◽  
High Strength Steels ◽  
Travel Speed ◽  
Pressure Vessels ◽  
High Deposition Rate ◽  
Hot Wire ◽  
Wire Feed

For high productivity weld fabrication, gas metal arc welding (GMAW) is typically used since it offers a combination of high deposition rate and travel speed. Recent advances in power supply technologies have increased the deposition rates in hot-wire tungsten inert gas (HW-TIG) welding, such that it is possible to achieve parameters which may be comparable to those used in GMAW for pressure vessels and some pipeline applications. However, these two processes have drastically different deposition efficiencies and heat input characteristics. The purpose of the present study is to examine GMAW and HW-TIG bead-on-plate deposits in terms of mechanical properties, deposition rate, and heat affected zone (HAZ) thermal cycles when identical travel speed and wire feed speeds are applied with a ER90S-G filler metal. The results demonstrate that HW-TIG can be applied with comparable travel and wire feed speeds to GMAW, while providing a more uniform weld bead appearance. Based on weld metal microhardness values, it is suggested the effective heat input is lower in HW-TIG compared to GMAW, since the average hardness of the weld metal is slightly higher.

scholarly journals Process Optimization on Multilayer Morphology During 316L Double-wire CMT+P Deposition Process

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1334
Author(s):  
Wei Wu ◽  
Jiaxiang Xue ◽  
Zhanhui Zhang ◽  
Xianghui Ren ◽  
Bin Xie
Keyword(s):  
Stainless Steel ◽  
Heat Input ◽  
High Efficiency ◽  
Speed Ratio ◽  
Optimum Process ◽  
Heat Accumulation ◽  
Forming Process ◽  
Cold Metal Transfer ◽  
Feeding Speed ◽  
Wire Feeding

Cold metal transfer (CMT) has been widely used in metal additive manufacturing for its low heat input, less splashing and high efficiency. Wire feeding speed and travelling speed are important processes that affect morphology in CMT deposition. This study optimized the forming process of 30-layer stainless-steel part deposited by double-wire and double-arc CMT plus pulse (CMT+P) process, and investigated the effect of the ratio of wire feeding speed to travelling speed on deposition morphology. The results show that asynchronous arc striking and extinguishing can improve the forming. Moreover, the deposition molding is affected by the interaction of heat input and heat accumulation. With the similar ratio of wire feeding speed to travelling speed and the similar heat input, increasing the wire feeding speed can increase the heat accumulation and the width of sample, and decrease the height. The optimum process interval of wire feeding speed to travelling speed ratio and heat input is 3.9–4.2 and 70–74.8 J/mm, respectively. Although the increasing heat accumulation makes grain coarse and slight decreases mechanical property, the highest deposition rate can be up to 5.4 kg/h, when wire feeding speed and travelling speed are 5 m/min and 120 cm/min, respectively, and the tensile strength and elongation rate of which can reach the basic standard requirements for stainless-steel forgings.

scholarly journals Experimental Investigation of Additive Manufacturing Using a Hot-Wire Plasma Welding Process on Titanium Parts

Materials ◽  
2021 ◽  
Vol 14 (5) ◽  
pp. 1270
Author(s):  
Pattarawadee Poolperm ◽  
Wasawat Nakkiew ◽  
Nirut Naksuk
Keyword(s):  
Grain Size ◽  
Additive Manufacturing ◽  
Manufacturing Industry ◽  
Welding Process ◽  
Ccd Camera ◽  
Hot Wire ◽  
Plasma Welding ◽  
Welding Wire ◽  
Wire Feeding ◽  
A Charge

In this paper, we propose hot-wire plasma welding, a combination of the plasma welding (PAW) process and the hot-wire process in the additive manufacturing (AM) process. Generally, in plasma welding for AM processes, the deposit grain size increases, and the hardness decreases as the wall height increases. The coarse microstructure, along with the large grain size, corresponds to an increase in deposit temperature, which leads to poorer mechanical properties. At the same time, the hot-wire laser process seems to contain an overly high interstitial amount of oxygen and nitrogen. With an increasing emphasis on sustainability, the hot-wire plasma welding process offers significant advantages: deeper and narrow penetration than the cold-wire plasma welding, improved design flexibility, large deposition rates, and low dilution percentages. Thus, the hot-wire plasma welding process was investigated in this work. The wire used in the welding process was a titanium American Welding Society (AMS) 4951F (Grade 2) welding wire (diameter 1.6 mm), in which the welding was recorded in real time with a charge-coupled device camera (CCD camera). We studied three parameters of the hot-wire plasma welding process: (1) the welding speed, (2) wire current, and (3) wire feeding speed. The mechanical and physical properties (porosity, Vickers hardness, microstructure, and tensile strength) were examined. It was found that the number of layers, the length and width of the molten pool, and the width of the deposited bead increased, while the height of the layer increased, and the hot-wire current played an important role in the deposition. In addition, these results were benchmarked against specimens created by a hot-wire plasma welding/wire-based additive manufacturing process with an intention to develop the hot-wire PAW process as a potential alternative in the additive manufacturing industry.

Droplet transfer behavior of narrow gap laser wire filling welding

2019 ◽  
Vol 33 (01n03) ◽  
pp. 1940045 ◽  
Author(s):  
Z. Zhang ◽  
R. Wang ◽  
G. Gou ◽  
H. Chen ◽  
W. Gao
Keyword(s):  
Welding Speed ◽  
High Speed ◽  
Transition Period ◽  
High Speed Photography ◽  
Narrow Gap ◽  
Droplet Transfer ◽  
Transfer Behavior ◽  
Feeding Speed ◽  
Wire Feeding ◽  
Droplet Transition

In this paper, we study the droplet transition behavior of narrow gap laser wire filling welding under the condition of changing welding speed and wire feeding speed, and it was observed by high-speed photography. It was found that with the increase of welding speed, the frequency of droplet transfer was reduced and the transition period was prolonged. With the increase of wire feeding speed, the wire was not fully melted and finally inserted into the molten pool.

Analytical Modeling of Metal Transfer for GMAW in the Globular Mode

2008 ◽  
Author(s):  
U. Ersoy ◽  
S. J. Hu ◽  
E. Kannatey-Asibu
Keyword(s):  
Gas Metal Arc Welding ◽  
Variable Mass ◽  
Welding Current ◽  
Metal Transfer ◽  
Model Parameters ◽  
Feeding Rates ◽  
Cycle Times ◽  
Metal Arc Welding ◽  
Wire Feeding ◽  
Spring Coefficient

A lumped parameter dynamical model is developed to describe the metal transfer for gas metal arc welding (GMAW) in the globular mode. The oscillations of molten drop are modeled using a mass-spring-damper system with variable mass and spring coefficient. An analytical solution is developed for the variable coefficient system to better understand the effect of various model parameters on the drop oscillations. The effect of welding drop motion on the observed current and voltage signals is investigated and the model agrees well with the experimental results. Furthermore, the effect of wire feeding rate (or welding current) on the metal transfer cycle time is studied and the model successfully estimates the cycle times for different wire feeding rates.

Welding Shape Control of Cross Member Backbone Assembly by Automatic Gas Metal Arc Yaskawa-MA1440 Type

2021 ◽  
Vol 877 ◽  
pp. 90-95
Author(s):  
Lydia Anggraini ◽  
Kalimi
Keyword(s):  
Shape Control ◽  
Gas Flow ◽  
Gas Metal Arc Welding ◽  
Travel Speed ◽  
Machine Construction ◽  
Weld Strength ◽  
Automatic Welding ◽  
Leg Length ◽  
Steel Coil ◽  
Cross Member

In order to prevent distortion caused by heat which affects the material deformation, the properties controlled are required. The properties changes and the placement of the mounting position will effect the weld strength that causes cracks and broken joints, therefore it affects the safety of machine construction. Thus, the objective of this paper is to control the shape of cross member backbone assembly by gas metal arc welding (GMAW). The welding is produced by an automatic robot Yaskawa-MA1440 type. In order to obtain the good quality of the result, the welding shape is controlled by a parameters combination of voltage, current, and speed. Yaskawa-MA1440 type is used as the automatic welding machine. The main material used is cold rolled steel coil sheet MJSC270D-OD with a thickness of 1.2 mm. In addition, to control the welding shape, the specified shape design standard is followed include travel speed, gas flow, welding direction, torch tip distance to the workpiece, torch angle and welding angle. The results of visual and dimensional were also examined in this research. Furthermore, the macrostructure i.e. leg length, fusion penetration, throat thickness have been analyzed and confirmed based on the standards used in the auto body vehicle part company. The appropriate parameters for the finest welding shape are defined at the horizontal position using an electric current of 120 A and the welding voltage of 18 V (± 1 V). Thus, the measurement control of macrostructure is defined as reference parameters for mass production of cross member backbone assembly.

Experimental investigation of laser hot-wire cladding

2015 ◽  
Vol 231 (6) ◽  
pp. 1007-1020 ◽  
Author(s):  
Shuang Liu ◽  
Wei Liu ◽  
Radovan Kovacevic
Keyword(s):  
Deposition Rate ◽  
Laser Power ◽  
Laser Scanning ◽  
Feeding Rate ◽  
Inconel 625 ◽  
Small Range ◽  
High Deposition Rate ◽  
Hot Wire ◽  
Cold Wire ◽  
Wire Feeding

Laser cladding by cold-wire feeding is known as an efficient cladding method due to its advantages, such as near 100% material utilization, high deposition rate, and flexible adaptation to the cladding position. However, it has very stringent requirements on the operative conditions, such as a small range of wire feeding rate and precise wire feeding position. The aim of this work was to investigate the laser hot-wire cladding technique, which improved the productivity and stability of the process significantly with respect to laser cold-wire cladding. The external preheating of the filler wire resulted in reduction in required laser power, a low dilution, and a higher deposition rate. A comparison was made between laser cold-wire cladding and laser hot-wire cladding of Inconel 625 on mild steel, with respect to the clad characteristics, microstructure, and hardness. An optimization of the main processing parameters in laser hot-wire cladding, such as the laser power, laser spot size, laser scanning speed, wire feeding orientation and position, wire preheating voltage, and wire feeding rate, was performed. The optimal parameters were used to create a multi-track deposit.

Microstructure and mechanical properties of double-wire feed GTA additive manufactured 308L stainless steel

2020 ◽  
Vol 26 (9) ◽  
pp. 1503-1513
Author(s):  
Yang Ke ◽  
Jun Xiong
Keyword(s):  
Mechanical Properties ◽  
Stainless Steel ◽  
Cooling Rate ◽  
Molten Pool ◽  
Heat Accumulation ◽  
Steel Component ◽  
Content Type ◽  
Wire Feeding ◽  
Novel Concept ◽  
Wire Feed

Purpose This paper aims to introduce a novel concept of a double-wire feed (DWF) to alleviate heat accumulation and improve the cooling rate of the molten pool in gas tungsten arc (GTA)-based additive manufacturing (AM), in which the former wire is fed into the arc and the latter wire is melt by the molten pool. Design/methodology/approach The microstructure, phase composition and mechanical properties of 308 L stainless steel components built by single-wire feed (SWF) AM and DWF-AM are compared, and the differences are analyzed in detail. Findings The microstructures for both wire feeding modes include δ and γ phases. Compared with the SWF-AM, the sample fabricated in the DWF-AM exhibits finer microstructure, and the microstructure in the middle region is transformed from columnar grains to cellular grains. Microhardness of the sample produced in the DWF-AM is higher than the SWF-AM. In comparison to the SWF-AM, the tensile strength of the specimen fabricated using the DWF-AM reaches 571 MPa and increases by 16.14%. Originality/value This study proposes a novel concept of the DWF-AM to reduce heat accumulation as well as enhance the cooling rate of the molten pool, and improved mechanical properties of the 308 L stainless steel component are obtained.

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