Systems to Control Molten Metal Transfer in Arc Welding

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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Analysis of Metal Transfer and Weld Forming Characteristics in Triple-wire Gas Indirect Arc Welding

10.21203/rs.3.rs-1154158/v1 ◽

2021 ◽

Author(s):

Liming Liu ◽

Zeli Wang ◽

Tianyi Zhang ◽

Xianli Ba

Keyword(s):

Electromagnetic Force ◽

Arc Welding ◽

Metal Transfer ◽

Force Model ◽

High Deposition Rate ◽

Transfer Mode ◽

Conductive Channel ◽

Forming Characteristics ◽

Metal Transfer Mode ◽

Indirect Arc

Abstract Triple-wire gas indirect arc welding (TW-GIA) has the advantages of low heat input and high deposition rate. However, the simultaneous melting of triple wires makes the metal transfer mode complicated. The unknown of the metal transfer mode restricts the development of this technology. In this paper, high-speed camera systems and electrical signal acquisition sensors were used to explore the TW-GIA metal transfer mode. The static force model and the arc conductive channel model were used to discuss the droplet force and energy conversion characteristics respectively. Results showed that the TW-GIA metal transfer modes can be divided into: short-circuit transfer (SCT), main wire projected transfer + side wire globular transfer (PGT), main wire streaming transfer + side wire projected transfer (SPT) and main wire streaming transfer + side wire streaming transfer (SST). Moreover, the process parameter ranges corresponding to the four modes were summarized. Due to the stable arc and the uniform metal transfer process, SPT and SST can form desirable weld seam. The gravity and z-axis components of electromagnetic force are the main forces that promote metal transfer. The x-axis and y-axis components of the electromagnetic force deviate the metal transfer path from the arc coverage. Due to the change of arc conductive channel, the energy transferred from TW-GIA to the base metal is less than that of GMAW, showing the advantages of small welding deformation, narrow heat affected zone and grain refinement.

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Analysis of metal transfer in gas metal arc welding

10.1063/1.5114003 ◽

2019 ◽

Author(s):

Emad Uddin ◽

Usman Iqbal ◽

Nabeel Arif ◽

Samiur Rehman Shah

Keyword(s):

Arc Welding ◽

Gas Metal Arc Welding ◽

Metal Transfer ◽

Metal Arc Welding

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The influence of bypass current on metal transfer in dual-bypass gas metal arc welding

Journal of Manufacturing Processes ◽

10.1016/j.jmapro.2019.01.015 ◽

2019 ◽

Vol 38 ◽

pp. 179-186 ◽

Cited By ~ 1

Author(s):

Jiangkang Huang ◽

Wei Pan ◽

Wenting Yang ◽

Cheng Xue ◽

Yu Shi ◽

...

Keyword(s):

Arc Welding ◽

Gas Metal Arc Welding ◽

Metal Transfer ◽

Metal Arc Welding

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