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.

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.

Stress Simulation for DE-GMAW in Bonding Steel with Aluminum

2011 ◽  
Vol 268-270 ◽  
pp. 24-29 ◽  
Author(s):  
Ming Liang Wu ◽  
Jian Kang Huang ◽  
Ri Hong Han ◽  
Yu Shi
Keyword(s):  
Residual Stress ◽  
Base Metal ◽  
Heat Input ◽  
Gas Metal Arc Welding ◽  
Source Model ◽  
Metal Arc Welding ◽  
Double Electrode ◽  
Melting Current ◽  
Metal Welding ◽  
Stress Simulation

DE-GMAW (Double-Electrode Gas Metal Arc Welding) is a new welding technology. It is possible to change the melting current while the base metal current still be controlled at a desired level because the changed part of the melting current would be bypassed without flowing through the workpiece. So the heat input of base metal can be controlled accurately in DE-GMAW, and this welding method is suitable for dissimilar metal welding which has strict requirements for heat input of base metal, such as joining of steel and aluminum. On the basis of heat source model of DE-GMAW, numerical simulation and analysis on temperature field and residual stress for DE-GMAW in bonding steel and aluminum were done. The results show that residual stress after welding changed sharply from close 0 MPa to about 130 MPa at the interface of aluminum and steel. This value is greater than the binding force of steel, aluminum interface.

Gas metal arc welding of XPF800 steel for automotive industry: Microstructural evaluation and mechanical properties investigation

2021 ◽  
pp. 146442072110567
Author(s):  
Emre Korkmaz ◽  
Cemal Meran
Keyword(s):  
Mechanical Properties ◽  
Base Metal ◽  
Automotive Industry ◽  
Heat Affected Zone ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Charpy Impact ◽  
Optical Microscope ◽  
Metal Arc Welding ◽  
Heat Affected Zone Softening

In this study, the effect of gas metal arc welding on the mechanical and microstructure properties of hot-rolled XPF800 steel newly produced by TATA Steel has been investigated. This steel finds its role in the automotive industry as chassis and seating applications. The microstructure transformation during gas metal arc welding has been analyzed using scanning electron microscope, optical microscope, and energy dispersive X-ray spectrometry. Tensile, Charpy impact, and microhardness tests have been implemented to determine the mechanical properties of welded samples. Acceptable welded joints have been obtained using heat input in the range of 0.28–0.46 kJ/mm. It has been found that the base metal hardness of the welded sample is 320 HV0.1. On account of the heat-affected zone softening, the intercritical heat-affected zone hardness values have diminished ∼20% compared to base metal.

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.

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.

An Evaluation System of Pulsed GMAW Process

2013 ◽  
Vol 483 ◽  
pp. 599-602
Author(s):  
Ying Gao ◽  
Jing Hua Han ◽  
Li Yan Lou ◽  
Huan Li
Keyword(s):  
Arc Welding ◽  
Evaluation System ◽  
High Speed ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Electric Signal ◽  
Characteristic Parameters ◽  
Display Module ◽  
Metal Arc Welding ◽  
Labview Platform

A process evaluation system for pulsed gas metal arc welding (GMAW-P) based on the LabVIEW platform has been developed. This system is comprised of two modules, a simultaneous display module and a data analysis module. Using these modules, the system can not only provide a comprehensive direct viewing display of the welding electric signal and high speed camera photo, but also can analyze the characteristic parameters of the welding process. The results show that the system works properly.

Modelling of bead hump formation in high speed gas metal arc welding

2016 ◽  
Vol 21 (8) ◽  
pp. 700-710 ◽  
Author(s):  
Guoxiang Xu ◽  
Qingnan Cao ◽  
Qingxian Hu ◽  
Weiwei Zhang ◽  
Peng Liu ◽  
...  
Keyword(s):  
Arc Welding ◽  
High Speed ◽  
Gas Metal Arc Welding ◽  
Metal Arc Welding
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