Effect of Thermal Frequency on AA6061 Aluminum Alloy Double Pulsed Gas Metal Arc Welding

Wang, Leilei; Jin, Li; Huang, Wenjin; Xu, Min; Xue, Jiaxiang

doi:10.1080/10426914.2015.1103863

Cited by 27 publications

(14 citation statements)

References 17 publications

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“…Wang et al [27] and Zhang et al [28] observed palpable weld ripples generated by DP-GMAW. The weld crest is produced at the end of the TP phase, whereas the weld trough is generated at the end of the TB phase.…”

Section: Weld Pool and Bead Characteristicmentioning

confidence: 99%

Perspective on Double Pulsed Gas Metal Arc Welding

Wang

Xue

2017

Applied Sciences

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Aluminum alloy welding suffers from problems such as solidification cracking and hydrogen-induced porosity, which are sufficiently severe to limit its potential applications. Because mitigated porosity incidence and solidification cracking are observed in aluminum welds using double pulsed gas metal arc welding (DP-GMAW), a comprehensive review of the mechanism is necessary, but absent from the literature. The oscillation of arc force and droplet pressure causes a weld pool stir effect. The expansion and shrinkage of the weld pool cause unusual remelting and resolidification of the previously solidified metal. DP-GMAW has an increased solidification growth rate and cooling rate, compared with conventional pulsed welding at same heat input. Both numerical and experimental results reveal the remarkable concept that refined microstructure in the fusion zone is obtained by using DP-GMAW. The mechanism of microstructural refinement is revealed as a weld pool stir effect and increased cooling rate. Hydrogen bubbles easily float out and then release from the weld pool originated from the weld pool stir effect. Reduced solidification cracking is achieved due to the refined solidification structure that originated from the increased cooling rate. The advantages, evolution process, and future trend of DP-GMAW are discussed.

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Section: Weld Pool and Bead Characteristicmentioning

confidence: 99%

Perspective on Double Pulsed Gas Metal Arc Welding

Wang

Xue

2017

Applied Sciences

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“…10,11 In recent studies, by implementing double pulsing technique, the number of passes was reduced to five, significantly reducing the total heat input. [12][13][14][15] Eventually, the toughness and strength are much improved in the double pulse GMAW (DP-GMAW) process as it is a comparatively low heat input and highly efficient welding process. [15][16][17][18] DP-GMAW cycle comprises a cyclic thermal pulse (TP) and a thermal base (TB) stage.…”

Section: Introductionmentioning

confidence: 99%

Characterization of weld joints produced by continuous wave and double pulse gas metal arc welding in naval grade high-strength low-alloy steel

Venkateshkannan

Natarajan

Rao

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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The current research examines gas metal arc welding (GMAW) joints generated in naval grade high-strength low-alloy (HSLA) steel using both continuous wave GMAW (CW-GMAW) and double pulse GMAW (DP-GMAW). The joint was created in four passes with DP-GMAW, whereas CW-GMAW required eight passes. Weld joints were characterized using various techniques, including optical microscopy (OM), scanning electron microscopy (SEM), residual stress analysis, and mechanical evaluation. The mechanical evaluation consisted of microhardness, impact, and tensile tests. The Charpy V-notch (CVN) impact test was performed at room temperature and −60°C. For both CW-GMAW and DP-GMAW, the heat-affected zone and the fusion zone were harder than the base metal. The fracture occurred in the base metal region in all the tensile test specimens containing the weld joints. The DP-GMAW joints showed higher impact toughness at both room temperature and −60°C. In comparison to the fusion zone of the CW-GMAW joint, the fusion zone of the DP-GMAW joint had a greater volume fraction of acicular ferrite, a finer grain size, and a higher percentage of high-angle grain boundaries. These factors have contributed, it is believed, to the higher impact toughness of the DP-GMAW joint.

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“…Some important and useful conclusions were drawn, however, the results lacked necessary support from the actual experiments, though there were important references for the experimental operations. Wang et al [19] researched the effect of thermal frequency, which was the frequency of the low-frequency current pulse for current modulation in DP-GMAW process, on the stability of the welding process, ripple distance, maximum penetration, and grain size and hardness of the fusion zone, though a series of experiments and measurements. The work revealed that the ripple distance reduces as the thermal frequency increases.…”

Section: Introductionmentioning

confidence: 99%

Effects of Operational Parameters on the Characteristics of Ripples in Double-Pulsed GMAW Process

2019

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This study focuses on the characteristics of the ripples of the weld bead formed during the double-pulsed gas metal arc welding (DP-GMAW) process. As a special output of the process, ripples include many useful information and can reflect the quality of the welding process. The work analyzed the operational characteristics of the DP-GMAW process based on robot operation which used the latest twinpulse XT DP control process, and then selected five key operational parameters, such as average current, welding speed, twin pulse frequency, twin pulse relation, and twin pulse current change in percent, to explore their effects on the formation and characteristics of ripples. A reliable method of measuring the distance of the ripples was used to provide convincing data. According to a series of experimental observations and analyses, the distance of ripples and appearance under different conditions were obtained. Also, curve fitting equations between each operational parameter and corresponding distances of ripples was obtained. To testify the effectiveness of the curve fitting equations, corresponding verifying experiments were conducted, and the results showed that all the errors were below 10%. In addition, the different levels of the operational parameters on the formation and characteristics of ripples were provided. This work can be a reference for the process and quality control improvement for the DP-GMAW process.

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Effect of Thermal Frequency on AA6061 Aluminum Alloy Double Pulsed Gas Metal Arc Welding

Cited by 27 publications

References 17 publications

Perspective on Double Pulsed Gas Metal Arc Welding

Perspective on Double Pulsed Gas Metal Arc Welding

Characterization of weld joints produced by continuous wave and double pulse gas metal arc welding in naval grade high-strength low-alloy steel

Effects of Operational Parameters on the Characteristics of Ripples in Double-Pulsed GMAW Process

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