Relationship between arc sound and subsidence of weld bead in aluminum alloy MIG welding process

2007 ◽  
Vol 43 (10) ◽  
pp. 32 ◽  
Author(s):  
Yu SHI
Keyword(s):  
Aluminum Alloy ◽  
Welding Process ◽  
Weld Bead ◽  
Mig Welding ◽  
Arc Sound

Modeling the Transport Phenomena During Hybrid Laser-MIG Welding Process

2003 ◽  
Author(s):  
Z. Zhou ◽  
W. H. Zhang ◽  
H. L. Tsai ◽  
S. P. Marin ◽  
P. C. Wang ◽  
...  
Keyword(s):  
Fluid Flow ◽  
Weld Pool ◽  
Solid Phase ◽  
Three Dimensional ◽  
Welding Process ◽  
Weld Bead ◽  
Mig Welding ◽  
Multiple Reflections ◽  
Computer Animations ◽  
Solidification Processes

Hybrid laser-MIG welding technology has several advantages over laser welding alone or MIG welding alone. These include the possibility of modifying weld bead shape including the elimination of undercut, the change of weld compositions, and the reduction of porosity formation in the weld. Although the hybrid laser-MIG welding method is becoming popular in industry, its development has been based on the trial-and-error procedure. In this paper, mathematical models and the associated numerical techniques were developed to calculate the heat and mass transfer and fluid flow during the laser-MIG welding process. The continuum formulation was used to handle solid phase, liquid phase, and mushy zone during the melting and solidification processes. The volume-of-fluid (VOF) method was employed to handle free surfaces, and the enthalpy method was used for latent heat. The absorption (Inverse Bremsstrahlung and Fresnel absorption) and the thermal radiation by the plasma in the keyhole, and multiple reflections at the keyhole wall were all considered in the models. The transient keyhole dynamics, interactions between droplets and weld pool, and the shape and composition of the solidified weld bead were all predicted for both the pulsed laser-MIG welding and three-dimensional moving laser-MIG welding. Computer animations showing the fluid flow, weld pool dynamics, and the interaction between droplets and weld pool will be shown in the presentation.

Effects of Macro and Microstructure of Aluminum Alloy AA 6063-T6 with TIG-AC Welding Process with Unbalanced Rectangular Wave

2017 ◽  
Vol 735 ◽  
pp. 65-69
Author(s):  
Jonny Max Catarino ◽  
Valter Roberto Brito Celestino ◽  
M.A.P. Bueno ◽  
I.D.D. Valarelli ◽  
M.C.S. Alves ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Oxide Layer ◽  
Welding Process ◽  
Weld Bead ◽  
Surface Oxide Layer ◽  
Positive Polarity ◽  
Negative Wave ◽  
Rectangular Wave ◽  
Positive Wave ◽  
Wave Cycle

The use of the rectangular wave in the TIG-CA welding process for aluminum alloys allows numerous possibilities of frequency control, wave amplitude variation and positive or negative current for the same wave cycle. The configuration selected is decisive for the effect and final property of the weld bead, where alternating current variation in aluminum alloy welding is widely used and is intended to promote surface oxide layer cleanliness while promoting penetration of the joint. In the literature it is common to find statements that the cleaning of the oxide layer at the welding time is connected to the positive wave cycle and the penetration is connected to the negative wave cycle time. For the research proposal, TIG-AC welding of the aluminum alloy AA 6063-T6 was performed by simple plate deposition with rectangular wave with variation both in the current and in the time of positive polarity of the electrode in the cycle in the current welding wave 140 A, For balance conditions at 50% of the positive polarity at a waveform time period of 20 ms, followed by wave unbalance to 32.5% and 15% of the positive polarity acting time maintaining a constant frequency of 50 Hz for all settings. The results for the selected settings show that the decrease in the positive wave time decreases the penetration and the width of the weld bead and this may be related to the selection of time and frequency used.

Study on DC Double Pulse MIG Welding of Automobile Aluminum Alloy

2011 ◽  
Vol 295-297 ◽  
pp. 1933-1937 ◽  
Author(s):  
Zhao Dong Zhang ◽  
Xiang Yu Kong
Keyword(s):  
Base Metal ◽  
Thin Sheet ◽  
Welding Process ◽  
Weld Bead ◽  
Double Pulse ◽  
Transfer Model ◽  
Al Alloy ◽  
Mig Welding ◽  
6061 Al Alloy ◽  
Better Than

In this paper, the features of weld formation, porosity, arc behavior, microstructure and mechanical properties of 6061 Al alloy thin sheet welds by direct current (DC) double pulse metal inert gas (MIG) welding process are investigated and compared with the traditional DC MIG welding process. Results show that continuous one-side welding with back forming weld beads without spatters, undercuts or cracks can be obtained by using the DC double pulse MIG welding process. The porosity of weld bead can be largely reduced by using the process. The arc of DC double pulse MIG welding is stable without arc blowout, and the metal transfer model of DC double pulse MIG welding is better than that of DC MIG welding. Microstructure of the weld bead by DC double pulse MIG welding shows a dendrite structure and it is fine and uniform. The average ultimate tensile strength and elongation of the weld bead by DC double pulse MIG welding can get to 228MPa, 80% of base metal, and 7.6%, 63% of base metal.

Weld Width Control System for Pulsed MIG Welding of Aluminum Alloy

2011 ◽  
Vol 299-300 ◽  
pp. 908-911
Author(s):  
Li Hui Lu ◽  
Ding Fan ◽  
Jian Kang Huang ◽  
Ming Zhu ◽  
Yu Shi
Keyword(s):  
Aluminum Alloy ◽  
Control System ◽  
Welding Process ◽  
Pulse Method ◽  
High Energy ◽  
Double Pulse ◽  
Mig Welding ◽  
Heat Accumulation ◽  
Weld Width ◽  
Vision Sensing

Due to strong heat accumulation and low surface tension of aluminum alloy, weld width will become wider, even subsidence in pulsed MIG welding process of aluminum alloy at constant parameters. A variable double-pulse method for weld width control is proposed. Weld width control is realized by changing double-pulse duty cycle that is the ratio of high-energy pulse time in a double-pulse cycle to adjust heat input based on the vision sensing for weld width. A rapid prototyping control system is built on the basis of vision sensing and xPC Target real-time environment. Then variable double-pulse MIG welding process test is done and proves the feasibility of the control scheme. On this basis, weld width control test in pulsed MIG welding of aluminum alloy is carried out and obtains a good weld with beautiful formation and uniform weld width. The results show that weld width control can be realized well with the variable double-pulse method in pulsed MIG welding of aluminum alloy.

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