Prevention of humping bead associated with high welding speed by double-electrode gas metal arc welding

Wu, Chuansong; Hu, Zeqi; Zhong, Lihui

doi:10.1007/s00170-012-3944-3

Cited by 27 publications

(13 citation statements)

References 9 publications

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“…Unfortunately, there are not enough experimental works to confirm or refute any of these theoretical models. Despite this, there is consensus that this undulation phenomenon happens mainly at high travel speeds (for instance, Wu et al [12] and Ye et al [13]). Nguyen at al.…”

Section: Introductionmentioning

confidence: 99%

Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

Yehorov

Silva

Scotti

2019

JMMP

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The purpose of the study was to propose a strategy to assess the potential reduction of the production cost during wire+arc additive manufacturing (WAAM) based on the combination of wire feed speed (related to deposition rate) and travel speed (related to deposition time). A series of experiments, using a multilayer-non-oscillated single pass wall made of an Al-Mg alloy, was conducted. The quality of the wall was assessed through the lateral surface waviness and top layer undulation. The concepts of Surface Waviness and Buy-to-Apply indices were introduced. Initially, the range of travel speed (TS) that provided layers with acceptable quality was determined for a given wire feed speed (WFS), corresponding to a constant current. Then, the effect of the increase of production capacity of the process (though current raising, yet maintaining the ratio WFS/TS constant) on the wall quality for a given condition within the TS range was assessed. The results showed that the useful range of TS prevents too rough a waving surface below the lower limit and top surface undulation over the higher limit. However, inside the range, there is little quality variation for the case under study. Finally, simulations of deposition time were developed to demonstrate the weight of the TS on the final deposition time and wall quality as a function of a target wall width. This respective weight showed the existence of a complex and unpredictable, yet determined, power of a combination of TS, target wall geometry, and dead time between subsequent layers. It was verified to be possible to find optimized TS as a function of different target geometries.

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Section: Introductionmentioning

confidence: 99%

Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

Yehorov

Silva

Scotti

2019

JMMP

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“…There are two main explanations for how the GTA can solve these problems. One is that the arc pressure of the GTA can directly pushes the liquid metal towards the sidewalls [16], forming the favorable weld bead formation. The other reason is that the GTA inputs extra heat in the weld pool, which can enhance the fluidity of the liquid metal [17].…”

Section: Effect Of the Gta On Weld Bead Formationmentioning

confidence: 99%

Analysis of process parameter effects during narrow-gap triple-wire gas indirect arc welding

Fang

2016

Int J Adv Manuf Technol

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Narrow-gap triple-wire gas indirect arc (TW-GIA) welding is a novel process. Previous studies have reported the process and explained how the wire arrangement affects the arc behavior and the metal transfer which correspondingly affect the sidewall fusion. In this paper, effects of process parameters on sidewall fusion, weld bead formation, microstructure, and hardness are studied, to reveal more characteristics of the narrow-gap TW-GIA. Results show that welding currents affect the sidewall penetration more significantly than groove gap and welding speed. In addition, sidewall penetration increases with larger welding currents. The heat affected zone (HAZ) width decreases with lower welding current, wider groove gap, or higher welding speed. With all the parameters, weld beads produced by narrow-gap TW-GIA present convex surfaces, which can lead to serious incomplete fusion at the weld root for the next weld layer. To solve this problem, addition of a gas tungsten arc (GTA) behind the TW-GIA is proposed. An additional benefit is that the arc pressure and extra heat input of the GTA obtain weld beads with concave surfaces.

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“…On the one hand, the shielding gas is isolated from the air to protect the welding zone form erosion; on the other hand, the shielding gas produces metallurgical action to improve joint performance. Compared with low-speed MIG, weld beads frequently occur in high-speed MIG, with weld defects such as hump weld bead, under cut, blowhole and surface oxidation [1][2][3][4][5][6][7]. At present, scholars worldwide have seldom studied weld forming after manual intervention [8][9][10][11][12][13][14].…”

Section: Introductionmentioning

confidence: 99%

High-Speed Welding of Stainless Steel with Additional Compensatory Gas Jet Blow Molten Pool

et al. 2018

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To avoid humping bead defects in high-speed welding, this paper proposes the method of an additional and compensatory gas jet blow molten pool. A pulsed metal inert gas high-speed welding test platform was constructed for compensatory gas jet blow molten pool. A total of 304 stainless steel sheets were used as the welding workpieces under equal heat inputs. Two high-speed butt welding processes were conducted and compared, in which the workpieces were welded with and without compensatory gas jets at 154 cm/min and 167 cm/min, respectively. After high-speed welding with compensatory gas jet blow, the weld appearance was straight, uniform, and high-quality, with no humping bead or undercut defects. The macroscopic morphologies and microstructures of cross-sections of the weld at the toe, near the surface, the middle, and the bottom portion all showed the stirring effect of the gas jet on the molten pool and improved grain refinement degrees. Hardness was enhanced in the weld center and the heat-affected zone. At welding speeds of 154 cm/min and 167 cm/min, the fracture load capacities of the welds were increased by 24.9 and 10.4%, respectively.

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Prevention of humping bead associated with high welding speed by double-electrode gas metal arc welding

Cited by 27 publications

References 9 publications

Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

Analysis of process parameter effects during narrow-gap triple-wire gas indirect arc welding

High-Speed Welding of Stainless Steel with Additional Compensatory Gas Jet Blow Molten Pool

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