Temperature determination of liquid metals is difficult but a necessary tool for improving materials and processes such as arc welding in the metal-working industry. A method to determine the surface temperature of the weld pool is described. A TIG welding process and absolute calibrated optical emission spectroscopy are used. This method is combined with high-speed photography. 2D temperature profiles are obtained. The emissivity of the radiating surface has an important influence on the temperature determination. A temperature dependent emissivity for liquid steel is given for the spectral region between 650 and 850 nm.
The paper presents a transient three-dimensional model of an anti-phase-synchronized pulsed tandem gasmetal arc welding process, which is used to analyze arc interactions and their influence on the gas shield flow. The shielding gases considered are pure argon and a mixture of argon with 18% CO 2. Comparison of the temperature fields predicted by the model with high-speed images indicates that the essential features of the interactions between the arcs are captured. The paper demonstrates strong arc deflection and kinking, especially during the low-current phase of the pulse, in agreement with experimental observations. These effects are more distinct for the argon mixture with 18% CO 2 . The second part of the paper demonstrates the effects of arc deflection and instabilities on the shielding gas flow and the occurrence of air contamination in the process region. The results allow an improved understanding of the causes of periodic instabilities and weld seam imperfections such as porosity, spatter, heat-tint oxidation and fume deposits.
The controlled metal transfer process (CMT) is a variation of the gas metal arc welding (GMAW) process which periodically varies wire feeding speed. Using a short-arc burning phase to melt the wire tip before the short circuit, heat input to the workpiece is reduced. Using a steel wire and a steel workpiece, iron vapour is produced in the arc, its maximum concentration lying centrally. The interaction of metal vapour and welding gas considerably impacts the arc profile and, consequently, the heat transfer to the weldpool. Optical emission spectroscopy has been applied to determine the radial profiles of the plasma temperature and iron vapour concentration, as well as their temporal behaviour in the arc period for different mixtures of Ar, O2 and CO2 as shielding gases. Both the absolute iron vapour density and the temporal expansion of the iron core differ considerably for the gases Ar + 8%O2, Ar + 18% CO2 and 100% CO2 respectively. Pronounced minimum in the radial temperature profile is found in the arc centre in gas mixtures with high Ar content under the presence of metal vapour. This minimum disappears in pure CO2 gas. Consequently, the temperature and electrical and thermal conductivity in the arc when CO2 is used as a shielding gas are considerably lower.
The controlled short-arc processes, variants of the gas metal arc welding (GMAW) process, which have recently been developed, are used to reduce the heat input into the workpiece. Such a process with a wire feeding speed which varies periodically, using a steel wire and a steel workpiece to produce bead-on-plate welds has been investigated. As welding gases CO2 and a mixture of Ar and O2 have been used. Depending on the gas, the properties of the plasma change, and as a consequence the weldseams themselves also differ distinctly. Optical emission spectroscopy has been applied to analyse the plasma. The radial profiles of the emission coefficients of an iron line and an argon line or an atomic oxygen line, respectively, have been determined. These profiles indicate the establishment of a metal vapour arc core which has a broader profile under CO2 but is more focused in the centre for argon. The measured iron line emission was near to its norm maximum in the case of CO2. From this fact, temperatures around 8000 K and a metal vapour molar fraction above 75% in the arc centre could be roughly estimated for this case. Estimations of the electrical conductivity and the arc field indicate that the current path must include not only the metal vapour arc core but also outer hot regions dominated by welding gas properties in the case of argon.
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