Sensing and Control of Double-Sided Arc Welding Process

[+] Author and Article Information
Y. M. Zhang, S. B. Zhang, M. Jiang

Welding Research Laboratory, Center for Robotics and Manufacturing Systems and Department of Electrical and Computer Engineering, University of Kentucky, Lexington, KY 40506

J. Manuf. Sci. Eng 124(3), 695-701 (Jul 11, 2002) (7 pages) doi:10.1115/1.1467603 History: Received November 01, 2000; Revised September 01, 2001; Online July 11, 2002
Copyright © 2002 by ASME
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Schematic diagrams of welding systems: (a) regular welding system (b) double-sided arc welding system
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Nonpenetrated keyhole and arc behavior: (a) nonpenetrated keyhole (b) arc divergence
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Penetrated keyhole and arc behavior: (a) penetrated keyhole (b) arc divergence
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Nonpenetrated and penetrated keyhole in DSAW: (a) nonpenetrated keyhole (b) penetrated keyhole
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Arc behaviors during keyhole welding. Welding current: 120 A, diameter of the orifice: 2.4 mm, flow rate of the orifice gas (argon): 1.8 L/min. (a) PAW (b) DSAW
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Welds made using DSAW process. Welding current: 70 A; Flow rate orifice gas (argon): 1.84 L/min; Diameter of orifice: 2.4 mm; Filler metal: none. (a) On 10 mm thick stainless steel plate at the flat position; Welding speed: 1.3 mm/s. (b) On 12.7 mm thick stainless steel plate at vertical-up position; welding speed: 0.83 mm/s.
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Weld pool transition after current decrease: (a) transient state 1: keyhole (b) transient state 2: complete weld pools (c) incomplete weld pools
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Proposed sensing and control system
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Illustration of current waveforms during controlled pulse keyhole DSAW: (a) waveform of currents (b) waveform of DSAW current
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Bead-on-plates welds made using controlled pulse keyhole DSAW process: thickness: 10 mm, material: stainless steel (type 304); filler metal: none. (a) flat position (b) vertical-down position
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Butt weld made using controlled pulse keyhole DSAW process: thickness: 13 mm, material: stainless steel (type 304), welding position: vertical-down, filler metal: none
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Butt weld made using controlled pulse keyhole DSAW process: thickness: 10 mm, material: DH36, mismatch: 2 mm, welding position: vertical-down, filler metal: none.



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