Algorithms for controlling inverter sources of welding current to optimize the electrode metal transfer parameters

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.

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Effect of Current Waveform on Metal Transfer in Controlled Short Circuiting Gas Metal Arc Welding

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.718-720.202 ◽

2013 ◽

Vol 718-720 ◽

pp. 202-208 ◽

Cited By ~ 1

Author(s):

Mao Ai Chen ◽

Yuan Ning Jiang ◽

Chuan Song Wu

Keyword(s):

Transfer Process ◽

High Speed ◽

Gas Metal Arc Welding ◽

Welding Current ◽

Metal Transfer ◽

Arc Voltage ◽

Metal Arc Welding ◽

Maximum Stability ◽

The Stability ◽

Welding Inverter

With high-speed welding inverter and precisely controlling the welding current with arc-bridge state, advanced pulse current waveforms can be produced to optimize the transfer characteristics of short circuiting transfer welding. In this paper, the images of droplet/wire, and the transient data of welding current and arc voltage were simultaneously recorded to study the influence of peak arcing current, background arcing current and tail-out time on the stability of short circuiting transfer process. It was found that maximum short circuiting transfer stability is reached under specific welding conditions. Any deviation from these conditions will cause abnormal rises in arc voltage indicating instantaneous arc extinguishing and greater spatter. Optimal welding conditions were obtained to achieve the maximum stability of short circuiting metal transfer process.

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Effect of Welding Current Waveforms on Metal Transfer and Weld Geometry in Controlled Short Circuiting Transfer GMAW

Journal of Mechanical Engineering ◽

10.3901/jme.2014.04.085 ◽

2014 ◽

Vol 50 (4) ◽

pp. 85 ◽

Cited By ~ 2

Author(s):

Maoai CHEN

Keyword(s):

Welding Current ◽

Metal Transfer ◽

Weld Geometry

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Effect of Laser on Frequency of Metal Transfer and Welding Current in Nd:YAG Laser+P-GMA Hybrid Welding

Chinese Journal of Lasers ◽

10.3788/cjl20103707.1908 ◽

2010 ◽

Vol 37 (7) ◽

pp. 1908-1913

Author(s):

秦国梁 Qin Guoliang ◽

林尚扬 Lin Shangyang

Keyword(s):

Nd:Yag Laser ◽

Welding Current ◽

Metal Transfer ◽

Hybrid Welding

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Dependence of Silicon and Manganese Content in the Weld Metal on the Welding Current and Method of Gas Shielding

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.756.92 ◽

2015 ◽

Vol 756 ◽

pp. 92-96 ◽

Cited By ~ 3

Author(s):

Dmitry A. Chinakhov

Keyword(s):

Chemical Composition ◽

Weld Metal ◽

Gas Dynamics ◽

Gas Flow ◽

Manganese Content ◽

Welding Current ◽

Mag Welding ◽

Different Types ◽

Considerable Impact ◽

Electrode Metal

The influence of the welding current and method of gas shielding in MAG welding on the content of silicon and manganese is considered. Results of study of the welded specimens of steels 45 and 30HGSA when applying welding wire of different formulas and different types of gas shielding (traditional shielding and two-jet shielding) are given. It is established that in MAG welding the value of the welding current and the speed of the gas flow from the welding nozzle have a considerable impact on the chemical composition of the weld metal. The consumable electrode welding under double-jet gas shielding provides the directed gas-dynamics in the welding area and enables controlling the electrode metal transfer and the chemical composition of a weld.

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Study on Metal Transfer and Welding Spatter Characteristics of Basic Flux Cored Wire

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.477-478.1369 ◽

2013 ◽

Vol 477-478 ◽

pp. 1369-1372 ◽

Cited By ~ 1

Author(s):

Yong Wang ◽

Ying Qiao Zhang ◽

Bao Wang ◽

Zhi Jun Wang

Keyword(s):

High Speed ◽

Short Circuit ◽

Welding Current ◽

Metal Transfer ◽

Welding Parameters ◽

Droplet Transfer ◽

Cored Wire ◽

Basic Flux ◽

Key Factor ◽

Slag Column

The metal transfer behaviors of basic flux cored wire at different arc voltage and welding current and the resultant welding spatter were investigated by using a high speed camera. Two modes of metal transfer are found: globular repelled transfer (lower welding parameters) and small droplet transfer (higher welding parameters). The former is accompanied by large granular spatter, large droplet itself explosion spatter and electric explosive spatter of short-circuit, and spatter in the latter is reduced obviously. But if the slag column is found in the two models, spatter could be dropped evidently owing to its significant guiding role for metal transfer. Therefore the slag column is the key factor of reducing welding spatter.

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