Optimization of hot-wire fraction for enhance quality in GMAW

Abstract

The combination of hot-wire insertion technology and gas metal arc welding (GMAW) is proposed to increase deposition rate and reduce power consumption. This study systematically investigated the effect of hot-wire fraction on weld metal properties. The results show that the compensatory deposition rate from hot-wire insertion provides a similar effective height compared with the rate from conventional GMAW, with a lower weld height/width ratio, lower power consumption, and improved mechanical properties. However, an excessive hot-wire fraction can lead to lack of fusion, and this value should be limited to no more than 44% of the total deposition rate. The relative GMAW and hotwire fractions were optimized to maximize total deposition volume while avoiding lack of fusion and providing sufficient penetration. With the optimized condition, hot-wire GMAW could be efficiently used to obtain similar deposition rates with lower power consumption and without sacrificing toughness properties. This proposed process offers a sustainable alternative development to conventional GMAW.

Selection of Welding Conditions for Achieving Both a High Efficiency and Low Heat Input for Hot-Wire Gas Metal Arc Welding

“…Welding processes that involve a hybridization of the hot-wire method (e.g., gas tungsten arc welding (GTAW), GMAW, submerged arc welding, laser welding) have been investigated and applied to improve productivity in fields beyond the construction machinery industry [11][12][13][14][15][16][17][18][19][20][21][22]. The welding phenomena and optimization of hot-wire feeding conditions have been investigated for the GTAW process [23].…”