Journal ArticleDOI
Metal Transfer in Double-Electrode Gas Metal Arc Welding
Kehai Li,YuMing Zhang +1 more
TLDR
In this paper, a double-electrode gas metal arc welding (DE-GMAW) was developed to increase the melting current while the base metal current can still be controlled at a desired level.Abstract:
Gas metal arc welding (GMAW) is the most widely used process for metal joining because of its high productivity and good quality, but analysis shows that the fundamental characteristic restricts conventional GMAW from further increasing the welding productivity. A novel GMAW process, refereed to as double-electrode GMAW or DE-GMAW, thus has been developed to make it possible to increase the melting current while the base metal current can still be controlled at a desired level. This fundamental change provides an effective method to allow manufacturers to use high melting currents to achieve high melting speed and low base metal heat input. A series of experiments have been conducted to uncover the basic characteristics of this novel process. Results obtained from analyses of high-speed image sequences and recorded current signals suggest that DE-GMAW can lower the critical current for achieving the desired spray transfer, shift the droplet trajectory, reduce the diameter of the droplet, and increase the speed and (generation) rate of the droplets.read more
Citations
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Journal ArticleDOI
Effects of activating flux on the welded joint characteristics in gas metal arc welding
TL;DR: In this paper, the effect of each welding parameter on the weld bead geometry was presented, and then the optimal process parameters were determined using the Taguchi method to determine the parameters, and the experimental results showed that activating flux aided GMAW increased the weld area and penetration and tended to reduce the angular distortion of the weldment.
Journal ArticleDOI
Study for TIG–MIG hybrid welding process
TL;DR: In this paper, the influence of the balance of current between the TIG and MIG arcs was investigated, which is most important in determining arc stability and arc penetration, and it was shown that the welding time can be reduced to 17 ~ 44 % of the time required using a conventional TIG process.
Journal ArticleDOI
Double-Electrode Arc Welding Process: Principle, Variants, Control and Developments
TL;DR: Double-electrode gas metal arc welding (DE-GMAW) is a novel welding process in which a second electrode, nonconsumable or consumable, is added to bypass part of the wire current.
Journal ArticleDOI
Usability of arc types in industrial welding
TL;DR: In this article, the types of welding arcs used in the welding industry, explains corresponding features and characteristics, provides guidance for suitable applications, and presents arc type comparisons, benefits, and weaknesses.
Journal ArticleDOI
Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions
TL;DR: In this paper, the authors view advanced welding manufacturing as a three-step approach: (1) pre-design that selects process and joint design based on available processes (properties, capabilities, and costs); (2) design that uses models to predict the result from a given set of welding parameters and minimizes a cost function for optimizing the welding parameters; and (3) real-time sensing and control that overcome the deviations of welding conditions from their nominal ones used in optimizing the weld parameters.
References
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Book
The Physics of Welding
TL;DR: In this paper, the authors describe electric arc welding, high energy density welding, and future developments of welding processes, and discuss the benefits of better understanding of the physics of welding.
Journal Article
Analysis of metal transfer in gas metal arc welding
Y.-S. Kim,Thomas W. Eagar +1 more
TL;DR: In this article, the static force balance theory and pinch instability theory as a function of welding current were used to predict the droplet sizes produced in GMAW using both the static forces balance theory (SFT) and the pinch instability (PIT) theory.
Journal ArticleDOI
Distribution of the heat and current fluxes in gas tungsten arcs
N. S. Tsai,Thomas W. Eagar +1 more
TL;DR: In this article, the distribution of heat flux on a water-cooled copper anode as a function of welding process parameters has been determined experimentally following an experimental technique developed previously, and the results indicate that arc length is the primary variable governing heat distribution and that the distribution is closely approximated by a gaussian function.
Journal ArticleDOI
Pressures produced by gas tungsten arcs
M. L. Lin,Thomas W. Eagar +1 more
TL;DR: In this article, the authors measured the pressure of tungsten welding arcs for currents from 300 to 600 amperes using argon and helium gases and showed that the pressure exerted by helium is a strong function of arc length.
Journal ArticleDOI
Modelling and analysis of metal transfer in gas metal arc welding
TL;DR: In this paper, a numerical model combining the methods of enthalpy, effective-viscosity and volume-of-fluid is developed to simulate the metal transfer process in gas metal arc welding.
Related Papers (5)
Consumable Double-Electrode GMAW -Part 1: The Process Arc stability, bypass current, and metal transfer mode were studied to better understand the fundamental issues of the process
K. H Li,Y. M Zhang +1 more
Double-electrode GMAW process and control : A novel welding process adds a GTAW torch to a conventional GMAW system to create a bypass arc for increasing melting current while controlling base current
K. H. Li,J. S. Chen,YuMing Zhang +2 more