High deposition rate pulse gas metal arc welding for Al 5083 thick plate

Abstract

The recent rapid advances in digital inverter-based welding power sources have allowed the realization of pulse gas metal arc welding, which can achieve stable metal transfer even at low welding current and thus reduce heat input to the base material. Moreover, a tandem-wire process using two electrodes can dramatically increase welding productivity. In such a process, two pulse power sources are synchronized and the interference between the adjacent welding arcs is minimized. In this study, high deposition rate pulse welding for Al 5083 alloy was implemented by using Al 5183 wire of three different diameters-1.6, 2.4, and 3.2 mm. Unlike the single-wire process, tandem-wire welding was only implemented using 1.6-mm-diameter wire. The bead shape, deposition rate, process windows, and stability were evaluated for each process. The results indicate that large wire diameters and the tandem process are preferable for high deposition rates, and the penetration depth is dependent on the welding current and speed. The tandem process achieves a remarkably high deposition rate, but spatter generation at high-current levels needs to be addressed. KeywordsGas metal arc welding, pulse welding, high deposition welding, Al 5083 alloy, thick plate, tandem, aluminum, pulsed gas metal arc welding, tandem gas metal arc welding, metal inert gas Date

Spatter Generation During Constant Voltage DC-AC Pulse Tandem Gas Metal Arc Welding Process

“…아크 용접공정에서 생산성과 용착량을 높이기 위한 방법으로 하나로 2개 이상의 와이어를 이용하는 탄뎀 (tandem) 용접공정이 적용되고 있다 [1][2][3][4][5] . 이러한 탄뎀 ORCID: Sanghoon Kang: http://orcid.org/0000-0002-2566-4570 ORCID: Hee-seon Bang: http://orcid.org/0000-0003-4891-5712 ORCID: Cheolhee Kim: http://orcid.org/0000-0003-4127-3171…”

High-deposition-rate position welding of Al 5083 alloy for spherical-type liquefied natural gas tank

“…The 2.4-mm single-wire process also exhibits considerably improved productivity, stable welding arc, and spatter suppression. 6…”

“…2 The authors previously investigated the characteristics of high-current welding of thick Al 5083 plates using single-wire welding and twin-wire welding in the flat position. 6 In this study, welding wires of diameters 1.6, 2.4, and 3.2 mm were used for single-wire welding, and two 1.6-mm-diameter wires were used for twin-wire welding. Twin-wire welding was effective for avoiding the formation of puckered beads, and single-wire welding exhibited better spatter suppression.…”

A comparative study between pulsed metal inert gas welding and continuous metal inert gas welding on thin Invar alloy

“…Ko¨se et al 16 used the pulsed DC robotic MIG welding method to weld the 5754 aluminum alloy sheets with different welding speed, in which the microstructure and mechanical properties of welded joint were studied. The pulsed MIG welding technology with high deposition rate was adopted on Al-5083 thick plate by Lee et al 17 The effect of wire size and different parameters on the morphology of joint was discussed in detail. Gao et al 18 investigated the effect of microstructure and mechanical properties of welded joint of 4N01 alloy by pulsed MIG welding.…”