Arc stability and its impact on weld properties and microstructure in anti-phase synchronised synergic-pulsed twin-wire gas metal arc welding

Moinuddin, Syed Quadir; Sharma, Abhay

doi:10.1016/j.matdes.2014.11.052

Cited by 56 publications

(17 citation statements)

References 18 publications

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“…The arc at either electrode passively heats another electrode that increases the overall melting efficiency [ 26 ]. The interaction between the arcs influences the arc stability [ 27 ], which directly affects the microstructures and properties [ 28 ]. In TP-GMAW, the welding currents at the two electrodes are pulsed with a time lag (phase difference) so that the arcs do not ignite at the same time.…”

Section: Introductionmentioning

confidence: 99%

Metallurgical Characterization of Penetration Shape Change in Workpiece Vibration-Assisted Tandem-Pulsed Gas Metal Arc Welding

et al. 2020

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Tandem-pulsed gas metal arc welding (TP-GMAW) simultaneously uses two wire-electrodes to enhance the material deposition rate, leading to the generation of a finger-shaped penetration as one of the arcs penetrates deeper than the other. On the other hand, workpiece vibration is one of the techniques used to control the microstructure of weld metal and a heat-affected zone. It is incidentally found that a specific vibration condition changes the finger-shaped penetration into pan-bottom shaped penetration in the TP-GMAW even though the vibration energy is much lower than the arc energy. Microstructure observation and elemental analysis are carried out for the welds fabricated without vibration and with three kinds of vibration modes, namely sine, random, and shock. The specific sine-mode vibration exhibits pan-bottom. The other modes of vibration in the same welding conditions exhibited invariable finger-shaped penetration. The Si atoms as a tracer distribute uniformly in the sine-mode. However, Si atoms segregate at the bottom of the finger-shaped weld metal with the random-mode and shock-mode workpiece vibrations. The weld pool shape change is prominent at a specific frequency. A resonance phenomenon between the droplet flow pattern and the molten material flow in the weld pool is likely to play a vital role in the change.

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Section: Introductionmentioning

confidence: 99%

Metallurgical Characterization of Penetration Shape Change in Workpiece Vibration-Assisted Tandem-Pulsed Gas Metal Arc Welding

et al. 2020

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“…Beside these, various predictive tools have been developed, such as mathematical models based on experimental results [1], artificial neural network (ANN) models [8], and numerical simulations [9]. Furthermore, many efforts have been carried out to highlight variables that affect weld penetration depth, such as shielding gas type [10,11], arc type [12], arc stability [13], gun angle [1], initial gap [14], welding current [15][16][17], arc voltage [15,18], and welding speed [15]. However, the limitation of having uncertainties in those welding parameters is not addressed.…”

Section: Introductionmentioning

confidence: 99%

A probabilistic model of weld penetration depth based on process parameters

Mansour

Zhu

Edgren

et al. 2019

Int J Adv Manuf Technol

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In welded structures using robotized metal active gas (MAG) welding, unwanted variation in penetration depth is typically observed. This is due to uncertainties in the process parameters which cannot be fully controlled. In this work, an analytical probabilistic model is developed to predict the probability of satisfying a target penetration, in the presence of these uncertainties. The proposed probabilistic model incorporates both aleatory process parameter uncertainties and epistemic measurement uncertainties. The latter is evaluated using a novel digital tool for weld penetration measurement. The applicability of the model is demonstrated on fillet welds based on an experimental investigation. The studied input process parameters are voltage, current, travel speed, and torch travel angle. The uncertainties in these parameters are modelled using adequate probability distributions and a statistical correlation based on the volt-ampere characteristic of the power source.Using the proposed probabilistic model, it is shown that a traditional deterministic approach in setting the input process parameters typically results in only a 50% probability of satisfying a target penetration level. It is also shown that, using the proposed expressions, process parameter set-ups satisfying a desired probability level can be simply identified. Furthermore, the contribution of the input uncertainties to the variation of weld penetration is quantified. This work paves the way to make effective use of the robotic welding, by targeting a specified probability of satisfying a desired weld penetration depth as well as predicting its variation.

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“…Improving the efficiency of welding production, achieving welding automation, and improving welding quality have become key issues in the development of welding technology [1]. Twin wire Double Pulsed Metal Inert Gas (GMAW) welding technology can perform high-speed welding and achieve a high deposition rate and is therefore considered a promising topic for research internationally [2][3][4] with many researchers being actively involved in related studies.…”

Section: Introductionmentioning

confidence: 99%

Effect of Additional Shielding Gas on Welding Seam Formation during Twin Wire DP-MIG High-Speed Welding

Xue

Dong

et al. 2018

Applied Sciences

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For diminishing welding defects such as incomplete penetration, which may easily occur during the twin wire Double Pulsed Metal Inert Gas (DP-MIG) high-speed welding, a novel method using additional shielding gas is introduced in this paper. A branch for the additional shielding gas was specially set near the back end of the protection hood for the DP-MIG nozzle. The constructed gas branch was used for enabling manual intervention in the formation of a high-temperature solid–liquid weld seam just emerging from the nozzle and also for secondary gas protection on the surface of the weld seam. The butt welding test was carried out in the 2205 duplex stainless steel plate and the weld seam was then characterized by a tensile test, metallographic analysis, X-ray non-destructive testing (NDT), hardness analysis, and impact test. The results showed that the introduction of an appropriate amount of additional shielding gas can effectively improve and diminish the unfused weld seam and also improve the mechanical properties such as the tensile properties of the weld joint, the hardness and toughness of the weld joints. Therefore, the introduction of additional shielding gas has further research potential in theory and process practice.

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Arc stability and its impact on weld properties and microstructure in anti-phase synchronised synergic-pulsed twin-wire gas metal arc welding

Cited by 56 publications

References 18 publications

Metallurgical Characterization of Penetration Shape Change in Workpiece Vibration-Assisted Tandem-Pulsed Gas Metal Arc Welding

Metallurgical Characterization of Penetration Shape Change in Workpiece Vibration-Assisted Tandem-Pulsed Gas Metal Arc Welding

A probabilistic model of weld penetration depth based on process parameters

Effect of Additional Shielding Gas on Welding Seam Formation during Twin Wire DP-MIG High-Speed Welding

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