Methods and results regarding sinusoid modulated pulse gas metal arc welding

Wang, Leilei; Heng, Gongchun; Chen, Hui; Xue, Jiaxiang; Lin, Fucai; Huang, Wenjin

doi:10.1007/s00170-015-8267-8

Cited by 12 publications

(9 citation statements)

References 18 publications

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“…The results indicate that DP-GMAW significantly reduces the mean grain dimension compared with CP-GMAW. Table 1 shows the microstructural refinement of aluminum alloy welds via DP-GMAW [16,[18][19][20]22,29]. The results indicate that DP-GMAW produces finer grain and dendrite than CP-GMAW with the same heat input; these experimentally observed results are powerful evidence that microstructural refinement can be achieved using DP-GMAW.…”

Section: Solidification Structurementioning

confidence: 84%

“…The welding current sharply decreases to a small value at the starting time of the TB phase; this little value current is occasionally insufficient to maintain the longest arc. Therefore, the actual welding operation suffers the high chance of arc quenching [22]. This "arc quenching drawback" reduces the welding process stability.…”

Section: Arc and Droplet Transfer Characteristicmentioning

confidence: 99%

“…The results indicated that both welds contained a certain amount of hydrogen-included pores, but DP-GMAW minimized the porosity incidence. Wang et al [22] found that the weld by CP-GMAW contained several pores, and fracture occurred at three continuous pores. Both the pore volume and number were reduced using DP-GMAW.…”

Section: Reduced Porosity Incidencementioning

confidence: 99%

“…Mathivanan et al [19,48] found that both yield strength and ultimate tensile strength could be increased by using DP-GMAW during welding of 6061 aluminum alloy and 310S austenitic stainless steel. Wang et al [22] found that ultimate tensile strength could by increased by using DP-GMAW due to reduced porosity incidence.…”

Section: Improved Solidification Cracking Susceptibilitymentioning

confidence: 99%

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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: Solidification Structurementioning

confidence: 84%

Section: Arc and Droplet Transfer Characteristicmentioning

confidence: 99%

Section: Reduced Porosity Incidencementioning

confidence: 99%

Section: Improved Solidification Cracking Susceptibilitymentioning

confidence: 99%

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Perspective on Double Pulsed Gas Metal Arc Welding

Wang

Xue

2017

Applied Sciences

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“…Under the circumstance, arc quenching may appear when actual currents switch between TPP and TBP, because the wire feeding equipment may not be able to catch up with the variation of the current pulse with adequate speed due to the mechanical inertia [8]. To alleviate the sudden changes of the current amplitude differences in these two phases, corresponding improvements have been revealed, such as trapezoid waveform, or sinusoidal waveform [8,9]. By means of the changes, the changes of the currents were replaced by gradual switches, which can improve the stability of the arc to achieve a stable droplet transfer [10].…”

Section: Introductionmentioning

confidence: 99%

Process and Parameter Optimization of the Double-Pulsed GMAW Process

Yao

Zhou

Huang

2019

Metals

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The double pulsed gas metal arc welding (DP-GMAW) process has been effectively employed to realize joining of steel plates and obtain weld bead surfaces with high quality fish scale ripples. In this work, a DP-GMAW process based on robot operation using the latest twinpulse XT DP control technology was employed to join the stainless-steel base plates. Four key operational parameters, which were robot welding speed, twin pulse frequency, twin pulse relation and twin pulse current change in percent, were selected to be input elements of orthogonal experimental design, which included nine experiments with three levels. To accurately understand the performance and process of weld bead obtained from DP-GMAW operation based on robot operation, the appearance observation and key shape parameters measurement, microstructure analysis, tensile and hardness testing, as well as stability analysis of the electrical signals, were conducted. Correlation analysis showed that the grain size was significantly correlative to the toughness and hardness. Then, to obtain quantitative evaluation results, fuzzy comprehensive evaluation (FCE) was employed to provide quality evaluation of weld beads from the above experiments. The influential levels of the key operational parameters on the appearance, grain size and FCE scores, and corresponding physical analyses, were respectively presented. In addition, optimal parameters combinations for obtaining weld beads with optimal appearance, grain size, and the highest FCE scores of weld bead quality were respectively provided according to the range analysis of the results from orthogonal experimental design. This work can provide an effective analysis method of influential levels of key operational parameters on the performance of the weld bead, optimal operational parameters combination seeking method, and quantitative quality evaluation method for the DP-GMAW process, which can improve the process optimization and increase the production efficiency, both in academic research and actual industrial production.

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