Modeling and simulation of the metal transfer on GMAW-S process

Abstract

The GMAW-S process occurs from sequences of arcing and short-circuit welding periods. For modeling purposes, many researchers believe that the metal transfer occurs only in the period of short circuit (consideration to be taken into account in the present work), in which the link between the electrode and the welding pool is generated through a liquid metal bridge. From this exact moment, it can be observed changes in the metal bridge geometry due to electromagnetic (pinch effect), gravitational, and surface tension forces. This paper is aimed to model the dynamic geometry of metal bridge during the shortcircuit period, considering the fusion and feed rate electrode wire balance. This model was represented by state equations building from applying Kirchoff's, Lorentz, Young-Laplace law, Bernoulli's principle, the equation of fluid continuity, and concepts of analytic geometry. The model implementation was developed in Simulink and could be used to study the metal transfer control, as well as, the appropriate welding parameters selection, aiming to achieve a higher level of welding quality.

Multivariable closed-loop control for layer geometry in Wire Arc Additive Manufacturing

“…This model describes the process behaviour in a globular-spray transfer mode. In Menezes et al (2019) a similar model for a GMAW process working in the shortcircuit transfer mode is proposed. to the material and the deposit cross section area A c .…”

Mild Steel GMA Welds Microstructural Analysis and Estimation Using Sensor Fusion and Neural Network Modeling

“…Among the most used metal joining processes, Gas Metal Arc-Welding (GMAW) stands out due to its high productivity and versatility, being used in several areas, for example, structural applications, manufacturing industries, and in the fabrication of devices and tools for industrial, domestic, medical, and scientific purposes—observing the limitations of dimensional precision. Also, it represents a competitive alternative to the processes with higher energy density, such as laser beam welding (LBW) and electron beam welding (EBW) [ 1 ] which motivates the various studies aimed at investigating the influence of the numerous process variables in the final microstructure [ 2 , 3 , 4 , 5 ]. The work performed by [ 2 ] proposed a hybrid modeling of metal bridge dynamic geometry in short-circuit GMAW for flat and orbital positions.…”

“…Also, it represents a competitive alternative to the processes with higher energy density, such as laser beam welding (LBW) and electron beam welding (EBW) [ 1 ] which motivates the various studies aimed at investigating the influence of the numerous process variables in the final microstructure [ 2 , 3 , 4 , 5 ]. The work performed by [ 2 ] proposed a hybrid modeling of metal bridge dynamic geometry in short-circuit GMAW for flat and orbital positions. The modeling of their work was implemented and proved to be effective in estimating the output parameters (position of the drop from the electrode tip, drop velocity, welding current, solid-state electrode length, and drop mass) providing an input data set.…”