Process Parameters Optimization for GMA Welding of AISI 1008 Steel Joints for Optimal Tensile Strength

Parameters optimization has become a gateway to achieving quality welds with improved properties desirable for construction and industrial applications. The complex interaction of welding input parameters requires process optimization to achieve optimal responses (s). This study reports the optimization of input parameters for Gas Metal Arc Welding (GMAW) for optimal ultimate tensile strength in AISI 1008 steel joints. Three levels of arc voltage, welding current, and gas flow rate were selected as input parameters, while the targeted output response is the ultimate tensile strength. Taguchi’s method with an L-9 orthogonal matrix was adopted for the process optimization. The MINITAB 17 software was used to analyze the response through analysis of variance and signal-to-noise ratio. The result revealed that the parameter settings for optimal tensile strength for the GMA welding of 6 mm thick AISI 1008 steel joint are arc voltage set at 30 V, current at 180 A, and gas flow rate set at 17 L/mm. The analysis of variance showed that the arc voltage had the most significant influence on the ultimate tensile strength with a 39.76% contribution, followed by the gas flow rate with 31.15%, while the welding current had 6.28% contributions. The surface plots show that a lower-level voltage, higher-level welding current, and higher-level gas flow rate favoured maximum ultimate tensile strength.

316L WAAM and pressure machining influence

Wire arc additive manufacture (WAAM) technology has a good development prospect, and can be used to manufacture large metal components with complex shapes in combination with traditional machining equipment. This paper adjusts the parameters from the perspective of heat input and arc control. It is found that the stacking quality of 316L stainless steel is the best when the arc voltage is 40V and the arc current is 360A. It is proposed to obtain the flat layers by pressure machining after every layer is stacked, which can create favorable conditions for manufacturing large-size components. And through the hot rolling experiment, it is proved that pressure machining can improve the density and uniformity of the microstructure, and thus enhance the comprehensive mechanical properties of components built by WAAM.

Influence of electron emission on operation of a constricted arc discharge in a pulsed forevacuum plasma-cathode electron source

The research of influence of electron emission and processes associated with the formation of a pulsed large-radius electron beam on operation of a constricted arc discharge, which forms emission plasma in a forevacuum plasma-cathode electron source, is presented. Processes, occurring in case of generation of the electron beam at forevacuum pressure range 3–20 Pa, provide lower operating voltage of the constricted arc discharge. The constricted arc voltage decreases with increasing pressure and increasing accelerating voltage. However, at pressure more than 15 Pa, the arc voltage decreases until a certain minimum value is reached, and then arc voltage is almost independent on pressure and accelerating voltage. This minimum value of the constricted arc voltage is on average 1.5–2 times higher as compared with voltage of the cathodic arc at the same discharge current. The observed decrease of operating voltage of the constricted arc is most likely caused by accelerated back-streaming ions, which move toward the emission electrode from beam-produced plasma. These accelerated ions partially penetrate into the hollow anode of discharge system through the mesh emission electrode and facilitate formation of the arc plasma, and thus provides lower voltage of the constricted arc.

Influence of Cusp External Magnetic Field on Deposition Rate of Two-electrode TIG Welding

Experiments have been conducted to investigate the influence of the cusp external magnetic field (EMF) on deposition rate of two-electrode tungsten insert gas (T-TIG) welding. T-TIG arc parameters such as arc shape, arc voltage, arc pressure and arc plasma information were acquired respectively. Results showed compared to TIG, a higher welding current could be allowed for T-TIG, due to its low arc pressure characteristic. Under the effect of the cusp EMF, the arc shape was compressed along x-axis of T-TIG, while elongated along y-axis of T-TIG. Besides, the peak arc pressure of T-TIG was not significantly increased by the cusp EMF. Moreover, with the action of the cusp EMF, the maximum values of the electron temperature (Te) and electron density (Ne) of T-TIG were not significantly increased, but along y-axis, the increments of the two parameters were gradually increased and their distributions were widened. Therefore, more arc energy was allocated on y-axis of T-TIG by the cusp EMF, which could improve the preheating and the melting of the filler wire along y-axis, so the deposition rate of T-TIG could be increased by 17.6% under the effect of the cusp EMF.

Modeling and Estimation of Break Arc Extinction Distance in Low Voltage DC Systems

Recently, as DC power generation and DC loads such as renewable energy and EVs increase, the need for a low-voltage direct current (LVDC) distribution system has gradually emerged. The DC system has various advantages, such as system stability, transmission efficiency, and connectivity to renewable power generation compared to AC distribution systems. One of the important technical issues for commercialization of DC distribution system is safety. Since the DC system does not have a current zero point, unlike the AC system, a breaking arc accompanied by a high-temperature plasma is easily generated when the circuit is cut off. The arc can cause fire accidents that threaten people and facilities. In order to prevent customers and facilities from the accidents caused by the arc in the DC system, a study on the characteristics of the DC breaking arc is necessary. An important factor of characteristics for the DC breaking arc fault is an arc extinction distance at which the DC breaking arc is completely extinguished. There are two major behaviors in DC breaking arc; one is active behavior where the arc voltage is inversely related with the arc current for a given gap distance, the other is passive behavior where the arc voltage is negatively proportional to the arc current according to Kirchhoff's voltage rule. This paper combines the two arc characteristics together to establish a DC breaking arc model, and proposes a method to estimate the arc extinction distance. Experiment results verify the method under various power and load conditions.