Showing papers on "Gas metal arc welding published in 2021"
TL;DR: In this paper, an Ultracold-Wire and Arc Additive Manufacturing (UC-WAAM) was proposed, in which the electric arc is established between the wire feedstock material and a non-consumable tungsten electrode.
54 citations
TL;DR: In this paper, a gas metal arc welding (GMAW) based wire arc additive manufacturing (WAAM) process has been employed to deposit 5-layered NiTi alloy on the Titanium substrate using Ni50.9Ti49.1 wire as the feedstock.
45 citations
TL;DR: This review begins with the GMAW-AM procedure, performance capability, identification of factors affecting the deposition performance, and strategies adopted to overcome these issues, and several aspects such as mathematical modelling, optimization, key process parameters, and their combinations for a wide range of wire electrode material and percentage contributions are reviewed and depicted in detail.
Abstract: Additive manufacturing (AM) route is a promising approach for fabricating complex and lightweight metallic structures that have applications in various sectors such as automotive, aerospace, and biomedical industries. Laser, electron beam, and electric arc are the common power sources available for AM. Out of different metal AM techniques, wire-feed additive manufacturing has been considered as a promising alternative for fabricating metallic parts for various applications. As it provides a high deposition rate, material utilization, density, and low cost with a low risk of contamination and porosity compared to powder-based raw material. Gas metal arc welding-based additive manufacturing (GMAW-AM) is a specific approach based on wire-feed AM. This technology uses a low-cost equipment which is suitable for fabricating components with large geometries and moderate structural complexity. These advantages attract the researchers and production industries for further developments in GMAW-AM to enhance its deposition performance, process capability, and applicability in various fields. The quality of metal deposited in GMAW-AM is generally represented by the surface form, dimensional quality, mechanical properties, relative density, hardness, etc. The present paper encompasses the research developments that occurred in the field of GMAW-AM in recent years. This review begins with the GMAW-AM procedure, performance capability, identification of factors affecting the deposition performance, and strategies adopted to overcome these issues. Several aspects such as mathematical modelling, optimization, key process parameters, and their combinations for a wide range of wire electrode material and percentage contributions are also reviewed and depicted in detail. Also, a comprehensive conclusion of this review, along with future perspectives, is explored subsequently. The current review work will help future researchers to select different wire materials and GMAW-AM parameters to achieve better performances. Lastly, several future research directions are suggested, specifically the need of a framework for GMAW-AM processes for fabricating quality products with minimum distortion.
44 citations
TL;DR: In this article, the authors compared three working modes for aluminum alloys: pulsed-GMAW mode, cold-arc mode and pulsed AC mode, and found that pulsedAC is more suitable for the use of aluminum alloy 5356.
40 citations
TL;DR: In this paper, a deep learning model was constructed using the monitoring image during the welding to predict the welding quality, and more than 95 % of estimated results of penetration depth were less 1 mm error for stepped and tapered sample shapes.
38 citations
TL;DR: In this paper, a fabrication method of producing metallic parts with overhanging structures using the multi-directional wire arc additive manufacturing was proposed, based on the metal droplet kinetics and weld bead geometry, two different Gas Metal Arc Welding (GMAW) metal transfer modes, namely short circuit transfer and free flight transfer, were evaluated.
34 citations
TL;DR: In this paper, a unified numerical model of variable polarity gas metal arc welding process is developed based on the solution of magnetohydrodynamic equations within the framework of the phase-field algorithm.
29 citations
TL;DR: RMD welding has been developed for a variety of steels to regulate the rate of metal transfer effectively during the short-circuiting mode of the GMAW process.
Abstract: RMD™ welding has been developed for a variety of steels to regulate the rate of metal transfer effectively during the short-circuiting mode of the GMAW process. To achieve the desired weld quality,...
28 citations
TL;DR: In this paper, a machine learning approach was used to predict the thermal field of multi-layer GMAW-based additive manufacturing (AM) processes with arbitrary geometries.
27 citations
TL;DR: In this article, the main joining process of aluminium alloys is discussed and two types of welding processes are of two types- solid state and liquid state welding, both of which have their own advantages and disadvantages.
26 citations
TL;DR: In this article, the machinability in terms of finishing milling of the welded surfaces and comparative analyses for ultrasonic-assisted milling processes were examined focussing on surface integrity.
Abstract: The supply and processing of materials for highly stressed components are usually cost-intensive. Efforts to achieve cost and resource efficiency lead to more complex structures and contours. Additive manufacturing steps for component repair and production offer significant economic advantages. Machining needs to be coordinated with additive manufacturing steps in a complementary way to produce functional surfaces suitable for the demands. Regarding inhomogeneity and anisotropy of the microstructure and properties as well as production-related stresses, a great deal of knowledge is still required for efficient use by small- and medium-size enterprises, especially for the interactions of subsequent machining of these difficult-to-machine materials. Therefore, investigations on these influences and interactions were carried out using a highly innovative cost-intensive NiCrMo alloy (IN725). These alloys are applied for claddings as well as for additive component manufacturing and repair welding using gas metal arc welding processes. For the welded specimens, the adequate solidification morphology, microstructure and property profile were investigated. The machinability in terms of finishing milling of the welded surfaces and comparative analyses for ultrasonic-assisted milling processes was examined focussing on surface integrity. It was shown that appropriate cutting parameters and superimposed oscillating of the milling tool in the direction of the tool rotation significantly reduce the mechanical loads for tool and workpiece surface. This contributes to ensure a high surface integrity, especially when cutting has to be carried out without cooling lubricants.
TL;DR: In this article, a robotic seam tracking system based on vision sensing and human-machine interaction for the multi-pass MAG welding was proposed, where the deviation could be judged by comparing the left or right groove edge alternatively with the corresponding specified positioning ruler from the real-time images obtained by industrial camera.
21 Apr 2021
TL;DR: In this article, a finite element model is presented for estimating the deformation of thin-walled parts using gas metal arc welding (GMAW) and a simulation model that predicts temperatures with less than 5% error and deformations of the final part.
Abstract: Gas Metal Arc Welding (GMAW) is a manufacturing technology included within the different Wire Arc Additive Manufacturing alternatives. These technologies have been generating great attention among scientists in recent decades. Its main qualities that make it highly productive with a large use of material with relatively inexpensive machine solutions make it a very advantageous technology. This paper covers the application of this technology for the manufacture of thin-walled parts. A finite element model is presented for estimating the deformations in this type of parts. This paper presents a simulation model that predicts temperatures with less than 5% error and deformations of the final part that, although quantitatively has errors of 20%, qualitatively allows to know the deformation modes of the part. Knowing the part areas subject to greater deformation may allow the future adaptation of deposition strategies or redesigns for their adaptation. These models are very useful both at a scientific and industrial level since when we find ourselves with a technology oriented to Near Net Shape (NNS) manufacturing where deformations are critical for obtaining the final part in a quality regime.
TL;DR: In this article, a framework for weld bead geometry prediction of GMAW process was developed by combining two machine learning techniques, i.e., deep learning and convolutional neural network, for real-time analysis.
TL;DR: In this paper, the state-of-the-art in real-time sensing of the gas metal arc welding process, including seam tracking, machine vision, weld pool monitoring, machine learning, etc.
TL;DR: A general and comprehensive framework for sustainability assessment of manufacturing processes is applied to select the most sustainable welding process among several alternatives for a certain application.
Abstract: Welding is a widely used manufacturing process that has a significant impact on the sustainability dimensions represented by environmental, economic and social aspects. In this work, a general and comprehensive framework for sustainability assessment of manufacturing processes is applied to select the most sustainable welding process among several alternatives for a certain application. The considered alternatives are friction stir welding (FSW), gas tungsten arc welding (GTAW), gas metal arc welding (GMAW), and shielded metal arc welding (SMAW). The four processes are used to weld two aluminum plates. Relevant sustainability indicators are selected from all sustainability dimensions. A dimension for physical performance of the welded parts is also considered. Entropy weight method is used for assigning weights to the indicators to avoid uncertainties of subjective weighting. Three multi-criteria decision making methods (MCDM) are used for normalization and aggregation of data. The reliability of the results is investigated by conducting sensitivity analysis. The results of the study show that FSW is the most sustainable welding process for this study.
TL;DR: In this article, the fatigue characteristics of SM490A, a material used in railway vehicles, were evaluated for welding and repair welding and finite element analysis (FEA) was conducted to evaluate the residual stress change.
TL;DR: In this paper, a computational fluid dynamics model of the weld pool considering the droplet impingement, gravity, arc force, heat and mass transfer for four typical welding position was developed, and the influence of gravity on the fluid flow for different position was investigated.
TL;DR: In this article, the authors describe the evergrowing needs in pipeline welding relating to quality, frequent usage of advanced, heat-sensitive, and corrosion-resistant materials alongside high production costs.
Abstract: Ever-growing needs in pipeline welding relating to quality, frequent usage of advanced, heat-sensitive, and corrosion-resistant materials alongside high production costs encourage the evaluation of...
TL;DR: In this paper, a backpropagation neural network (BPN) was used to predict angular distortions in high-strength steel, Hardox 450®, welded by gas metal arc welding (GMAW) single-pass butt welding process on different sizes and thicknesses thin plates.
TL;DR: Fracture resistance of pipeline welds from a range of strength grades and welding techniques was measured in air and 21MPa hydrogen gas, including electric resistance weld, friction stir weld of X100 and gas metal arc welds (GMAW) as discussed by the authors.
TL;DR: In this article, an overview of publications on arc welding of zirconium and its alloys for seven decades is provided, where the main attention is paid to the parameters of the gas tungsten arc, plasma arc, and gas metal arc welding methods.
TL;DR: In this article, the hot corrosion resistance of the wrought alloy 625 and the alloy 625 GMAW cladding was investigated in the molten salt mixture of 47 PbSO4-23 ZnO-13 Pb3O4-7 PbCl2-x CdO-(10-x) Fe2O3 [x = 5] (wt.%) at 600, 700, and 800 °C, utilizing EIS, OCP, potentiodynamic polarization, weight-loss measurement, SEM/EDX, ICP/AAS, and XRD
TL;DR: This work is a preliminary study intended to develop an in-process monitoring system that can identify and classify the defects in GMAW process and its efficiencies are reported.
01 May 2021
TL;DR: The steel wall measuring 120'mm in length and 210'm in height was manufactured by wire and arc additive manufacturing (WAAM) using ER347 wire and gas metal arc welding (GMAW) as discussed by the authors.
Abstract: The steel wall measuring 120 mm in length and 210 mm in height was manufactured by wire and arc additive manufacturing (WAAM) using ER347 wire and gas metal arc welding (GMAW). The mechanical integ...
TL;DR: In this paper, the authors investigated the WRS and deformation induced by LVEBW and metal active gas arc welding (MAG) in SUS310S thick-plate joint via numerical simulation and experiment.
Abstract: Local vacuum electron beam welding (LVEBW) breaks through the limit of vacuum chamber and can be flexibly proceeded in more working conditions. Using LVEBW to substitute conventional gas metal arc welding will greatly improve production efficiency. In view of the severe effect of welding residual stress (WRS) on product safety, the WRS induced by two methods should be comprehensively evaluated, thus for providing the designer and engineer with a theoretical basis and guidance to control the WRS in thick-plate joint. This paper investigated the WRS and deformation induced by LVEBW and metal active gas arc welding (MAG) in SUS310S thick-plate joint via numerical simulation and experiment. Based the simulation and experiment results, the WRS and deformation induced by the LVEBW and MAG were compared quantitatively. Results show that the distribution of WRS induced by two methods are significantly different. The high longitudinal residual stress (RS) region in LVEBW joint is much narrower than that in MAG joint and the maximum transverse RS in LVEBW joint is smaller than that in MAG joint. Both the transverse shrinkage and out-of-plane deformation induced by LVEBW is far less than that induced by MAG. Meanwhile, LVEBW has a great efficiency advantage over MAG.
TL;DR: In this paper, two-dimensional axisymmetric heat source distributions of the arc plasma were obtained by a grid-based simulation and a particle-based method that couples the discrete element method (DEM) and incompressible smoothed particle hydrodynamics (ISPH) were then applied to verify the mechanisms of slag and weld pool formation and the thermal effects of flux and slag on the base metal, weld pool and weld bead.
TL;DR: In this paper, the effect of different individually controllable input parameters like wire feed rate, welding speed, voltage, standoff distance and torch angle on the resulting angular distortion of Stainless Steel 202 plates was investigated.
TL;DR: In this article, the effect of filler wires on the microstructure and mechanical properties of joint was investigated, and the carbide precipitates were contrastively discussed; the results revealed that the micro-structure of weld metal, heat-affected zone and base metal are austenite.
TL;DR: In this article, an effort is made to optimize the welding parameters namely, welding current, voltage and bevel angle for obtaining better impact strength of dissimilar joining of SA387 alloy steel with the stainless steel grade of SS304 using Taguchi L9 orthogonal array.