A Way to Weld Sheet Metal with Double-Electrode GMAW

2013 ◽  
Vol 651 ◽  
pp. 333-337 ◽  
Author(s):  
Guo Hong Ma ◽  
Yu Ming Zhang
Keyword(s):  
Arc Welding ◽  
High Speed ◽  
Gas Metal Arc Welding ◽  
Metal Transfer ◽  
Constant Current ◽  
Spray Transfer ◽  
Metal Arc Welding ◽  
Globular Transfer ◽  
Double Electrode ◽  
Welding System

This paper designed a double-electrode GMAW(gas metal arc welding) system. This system includes main arc and bypass arc. Main arc (Base metal current: Ibm) is supplied with Constant Current power (CC mode) and bypass arc (bypass current: Ibp) is Constant Voltage power (CV mode). Main arc electrode used common carbon wire, bypass arc electrode used water cool copper. Welding experiment shows this DE-GMAW can change common metal transfer into spray transfer with lowest critical total current (Itotal) 200 amps. When Ibm decreases and bypass voltage increases, this critical current will increase and it is less than 230 amps when keeping spray transfer. High speed video proved that metal transfer is changed from spray transfer to globular transfer.

Metal Transfer in Double-Electrode Gas Metal Arc Welding

2007 ◽  
Vol 129 (6) ◽  
pp. 991-999 ◽  
Author(s):  
Kehai Li ◽  
YuMing Zhang
Keyword(s):  
Base Metal ◽  
Arc Welding ◽  
High Speed ◽  
Gas Metal Arc Welding ◽  
High Melting ◽  
High Productivity ◽  
Spray Transfer ◽  
Metal Arc Welding ◽  
Double Electrode ◽  
Melting Current

Gas metal arc welding (GMAW) is the most widely used process for metal joining because of its high productivity and good quality, but analysis shows that the fundamental characteristic restricts conventional GMAW from further increasing the welding productivity. A novel GMAW process, refereed to as double-electrode GMAW or DE-GMAW, thus has been developed to make it possible to increase the melting current while the base metal current can still be controlled at a desired level. This fundamental change provides an effective method to allow manufacturers to use high melting currents to achieve high melting speed and low base metal heat input. A series of experiments have been conducted to uncover the basic characteristics of this novel process. Results obtained from analyses of high-speed image sequences and recorded current signals suggest that DE-GMAW can lower the critical current for achieving the desired spray transfer, shift the droplet trajectory, reduce the diameter of the droplet, and increase the speed and (generation) rate of the droplets.

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.

scholarly journals Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2457
Author(s):  
Oleg Panchenko ◽  
Dmitry Kurushkin ◽  
Fedor Isupov ◽  
Anton Naumov ◽  
Ivan Kladov ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Arc Welding ◽  
High Speed ◽  
Gas Metal Arc Welding ◽  
Metal Transfer ◽  
Process Data ◽  
Cold Metal Transfer ◽  
Wall Width ◽  
Metal Arc Welding ◽  
Wire Arc Additive Manufacturing

In wire arc additive manufacturing of Ti-alloy parts (Ti-WAAM) gas metal arc welding (GMAW) can be applied for complex parts printing. However, due to the specific properties of Ti, GMAW of Ti-alloys is complicated. In this work, three different types of metal transfer modes during Ti-WAAM were investigated: Cold Metal Transfer, controlled short circuiting metal transfer, and self-regulated metal transfer at a direct current with a negative electrode. Metal transfer modes were studied using captured waveform and high-speed video analysis. Using these modes, three walls were manufactured; the geometry preservation stability was estimated and compared using effective wall width calculation, the microstructure was analyzed using optical microscopy. Transfer process data showed that arc wandering depends not only on cathode spot instabilities, but also on anode processing properties. Microstructure analysis showed that each produced wall consists of phases and structures inherent for Ti-WAAM. α-basketweave in the center of and α-colony on the grain boundary of epitaxially grown β-grains were found with heat affected zone bands along the height of the walls, so that the microstructure did not depend on metal transfer dramatically. However, the geometry preservation stability was higher in the wall, produced with controlled short circuiting metal transfer.

Analysis and Improvement of Metal Transfer Behaviors in Consumable Double-Electrode GMAW Process

2015 ◽  
Vol 137 (1) ◽  
Author(s):  
Ming Zhu ◽  
Yu Shi ◽  
Ding Fan
Keyword(s):  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Metal Transfer ◽  
Force Balance ◽  
Current Electrode ◽  
Main Metal ◽  
Metal Arc Welding ◽  
Weld Appearance ◽  
Double Electrode ◽  
Welding Consumable

Consumable double-electrode gas metal arc welding (consumable DE-GMAW) is the efficient improvement of DE-GMAW. Due to the variety of coupled arc and metal transfer behaviors, this paper applies static force balance theory to analyze the changes in the forces acting on the main and bypass droplets separately. For main torch, the bypass arc changes the forces affecting on the main droplet, and the main metal transfer becomes more desirable. For bypass torch, with direct current electrode negative (DCEN) polarity, the volume of droplet is big and not easily transfers to the weld pool. In order to improve the bypass metal transfer, a method has been proposed which adds CO2 to pure argon shielding gas to change the forces affecting on the bypass droplet. Then, the welding experiment is carried out to test the effectiveness of this method. It is found that bypass droplet transfers easily and the diameter of bypass droplet is decreased significantly. Also a good weld appearance is acquired.

Effect of Arc Length on Weld Appearance and Metal Transfer in Twin-Wire GMAW Process

2012 ◽  
Vol 472-475 ◽  
pp. 1279-1282 ◽  
Author(s):  
Huan Ming Chen ◽  
Shao Jie Wu
Keyword(s):  
Transfer Process ◽  
Arc Welding ◽  
High Speed ◽  
Metal Transfer ◽  
High Speed Camera ◽  
Arc Length ◽  
Process Stability ◽  
Spray Transfer ◽  
Weld Appearance ◽  
Globular Transfer

The experiments were performed with the twin-wire GMAW machine of Fronius product. The metal transfer process and the arc shapes were observed by use of shadowgraph technique with a high-speed camera. When the arc length increases during twin-wire CO2 arc welding, the mode of metal transfer changes from short-circuiting transfer to globular transfer, and to spray transfer. But it is difficult to form a stable spray transfer process, and the weld appearance becomes worse. The short-circuiting transfer in twin-wire CO2 arc welding can improve the process stability.

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

2013 ◽  
Vol 718-720 ◽  
pp. 202-208 ◽  
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.

scholarly journals Analysis of metal transfer in gas metal arc welding

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

Effect of DE-GMAW (Double Electroda Gas Metal Arc Welding)’s Resistance on Mechanical and Physical Properties of Aluminium Alloy Weld

2018 ◽  
Vol 789 ◽  
pp. 64-68
Author(s):  
Yustiasih Purwaningrum ◽  
Medilla Kusriyanto ◽  
Rudi Kurniawan ◽  
Okto Akbar Rizky
Keyword(s):  
Physical Properties ◽  
Aluminium Alloy ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Weld Metals ◽  
Metal Arc Welding ◽  
Mechanical And Physical Properties ◽  
Double Electrode ◽  
Gmaw Welding

This paper presented the effect of DE-GMAW (Double electrode gas metal arc welding)resistance on mechanical and physical properties of aluminium alloywelded. DE-GMAWis amethodof welding process that use two electrode. A non consumable torch is added to bypass the current inorder to reduce the heat input. The variation resistance used were 15Ω, 30Ω and 45Ω. Universaltesting machine and Vickers microhardness were used to measured mechanical properties of weldmetals with respect to strength and hardness. The microstructure was investigated by microscopeoptic with 100 x magnification. The grain size of weld metals with resistance value 30Ω is finer than15Ω and 45Ω. Dye penetrant test shows DE-GMAW welding machine that made have goodperformance because it can produce welding joint without surface crack. The results show thatresistance values optimum to DE-GMAW welding on aluminium alloy 5051 with 4 mm thickness is30Ω. It can be seen from the tensile test that shows the highest tensile strength is found in the DEGMAWwelding with resistance values 30Ω.

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

2019 ◽  
Vol 38 ◽  
pp. 179-186 ◽  
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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