Indirect approaches for estimating the efficiency of the cold metal transfer welding process

Mezrag, Bachir; Deschaux-Beaume, Frédéric; Rouquette, Sébastien; Benachour, Mustapha

doi:10.1080/13621718.2017.1417806

Cited by 12 publications

(8 citation statements)

References 22 publications

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“…The presented method, which includes (i) calculation of the temperature at the bonding interface between the steel sheet and the aluminum weld by means of finite element (FE) simulation, (ii) validation of the obtained numerical results with temperature curves measured in CMT welding, (iii) prediction of the thickness of the IM layer based on the calculated temperature field, and finally (iv) validation of the predicted thickness with micrographs of weld cross-sections, has already been presented by the authors of this article [63]. This method was also successfully applied by Borrisutthekul et al [64] for estimating the effect of different heat flow control measures on the thickness of the IM layer in laser welding, and by Mezrag et al [65] for the indirect determination of the process efficiency in CMT welding.…”

Section: Introductionmentioning

confidence: 80%

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Calculation of the Intermetallic Layer Thickness in Cold Metal Transfer Welding of Aluminum to Steel

et al. 2018

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The intermetallic layer, which forms at the bonding interface in dissimilar welding of aluminum alloys to steel, is the most important characteristic feature influencing the mechanical properties of the joint. In this work, horizontal butt-welding of thin sheets of aluminum alloy EN AW-6014 T4 and galvanized mild steel DC04 was investigated. In order to predict the thickness of the intermetallic layer based on the main welding process parameters, a numerical model was created using the software package Visual-Environment. This model was validated with cold metal transfer (CMT) welding experiments. Based on the calculated temperature field inside the joint, the evolution of the intermetallic layer was numerically estimated using the software Matlab. The results of these calculations were confirmed by metallographic investigations using an optical microscope, which revealed spatial thickness variations of the intermetallic layer along the bonding interface.

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Section: Introductionmentioning

confidence: 80%

“…The efficiency of the welding process, η, is in the range of about 0.8–0.9 for energy-reduced GMA welding processes with controlled dip transfer [65,66,67]. However, η tends to increase with decreasing arc power [67].…”

Section: Methodsmentioning

confidence: 99%

Calculation of the Intermetallic Layer Thickness in Cold Metal Transfer Welding of Aluminum to Steel

et al. 2018

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“…Argon is used as inert gas with a flow of 25 L/min. The set of welding parameters are listed Table 1 and the arc efficiency was set to 0,83 [29]. These parameters are chosen to be close to the future use case of the simulation.…”

Section: Model Validationmentioning

confidence: 99%

An indicator of porosity through simulation of melt pool volume in aluminum wire arc additive manufacturing

Béraud

Chergui

Limousin³

et al. 2022

Mechanics & Industry

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Managing the quality of functional parts is a key challenge in wire arc additive manufacturing. In case of additive production of aluminum parts, porosity is one of the main limitations of this process. This paper provides an indicator of porosity through the simulation of melt pool volume in aluminum wire arc additive manufacturing. First, a review of porosity formation during WAAM process is presented. This review leads to the proposal of this article: monitoring the porosity inside produced part can be achieved through the melt pool volume monitoring. An adapted Finite Element model is then proposed to determine the evolution of the melt pool volume throughout the manufacturing process of the part. This model is validated by experimental temperature measurement. Then, in order to study the link between the porosity and the melt pool volume, two test parts are chosen to access to two different pore distributions. These two parts are simulated and produced. The porosity rates of produced parts are then measured by X-ray tomography and compared to the simulated melt pool volumes. The analysis of the results highlights the interest of the melt pool volume as a predictive indicator of the porosity rate.

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“…In addition, pulsed GMAW (GMAW-P) maintained the arc in the pulse base stage and melted wire in the pulse peak stage, thus achieving the controlled metal transfer process (Refs. [17][18][19]. Compared with conventional GMAW, GMAW-P could be widely used in manufacturing because of better deposition efficiency and weld quality .…”

Section: Abstract • Droplet Transfer • Voltage-current Characteristicmentioning

confidence: 99%

Characteristics of Magnetic Field Assisting Plasma GMAW-P

Yu¹,

Wang²,

Zhang³

et al. 2020

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The droplet transfer and voltage-current characteristics of gas metal arc welding (GMAW) in single-pulsed GMAW (single GMAW-P), plasma pulsed GMAW (plasma GMAW-P), and plasma-GMAW-P with a magnetic field were studied using the synchronous acquisition system of high-speed camera and electric signals. The results showed the plasma arc and magnetic field had a significant effect on the droplet transfer process. The indirect arc of the plasma and gas metal arc emerged in the pulse peak phase causing a shunt phenomenon of the GMAW current. The period of the indirect arc was increased under the action of the magnetic field. In hybrid plasma GMAW-P, when the GMAW current did not exceed 140 A, several pulsed one-drop free transfers occurred and the droplet transfer period decreased with the increase in the plasma welding current; when the GMAW current exceeded 140 A, and the plasma welding current was less than 180 A, spray transfer was formed. The droplet transfer transformed into a projected transfer when the plasma welding current increased to 180 A. In plasma-GMAW-P hybrid welding with a magnetic field, the magnetic field had a slight effect on the transfer period. When the GMAW current did not exceed 140 A, the droplet transfer was mainly repelled transfer. The detaching location was on the right side of the wire when the magnetic field current was less than 3 A. When the magnetic field current exceeded 3 A, it was below or on the left side of the wire. When the GMAW current exceeded 140 A and the magnetic field current was less than 5 A, spray transfer was formed, but the droplet transfer mode transformed into a projected transfer with a magnetic field current of 5 A.

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Indirect approaches for estimating the efficiency of the cold metal transfer welding process

Cited by 12 publications

References 22 publications

Calculation of the Intermetallic Layer Thickness in Cold Metal Transfer Welding of Aluminum to Steel

Calculation of the Intermetallic Layer Thickness in Cold Metal Transfer Welding of Aluminum to Steel

An indicator of porosity through simulation of melt pool volume in aluminum wire arc additive manufacturing

Characteristics of Magnetic Field Assisting Plasma GMAW-P

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