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TECHNICAL PAPERS

Metal Transfer in Double-Electrode Gas Metal Arc Welding

[+] Author and Article Information
Kehai Li, YuMing Zhang

Center for Manufacturing and Department of Electrical and Computer Engineering, University of Kentucky, Lexington, KY 40506

J. Manuf. Sci. Eng 129(6), 991-999 (Jun 09, 2007) (9 pages) doi:10.1115/1.2769729 History: Received August 10, 2006; Revised June 09, 2007

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.

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Copyright © 2007 by American Society of Mechanical Engineers
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Figures

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Figure 1

Conventional GMAW system and process

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Figure 2

Previous experimental system for double-electrode gas metal arc welding

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Figure 3

Proposed DE-GMAW system

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Figure 4

Geometrical parameters in DE-GMAW

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Figure 5

Experiment 1, WFS: 5.1m∕min(200IPM)

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Figure 6

Experiment 2, WFS: 6.4m∕min(250IPM)

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Figure 7

Experiment 3, WFS: 7.1m∕min(280IPM)

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Figure 8

Experiment 4, WFS: 14m∕min(550IPM)

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Figure 9

Metal transfer in experiment 1, WFS: 5.1m∕min(200IPM)

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Figure 10

Metal transfer in experiment 2, WFS: 6.4m∕min(250IPM): (a), (b), and (c) used different bypass currents

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Figure 11

Metal transfer in experiment 3, WFS: 7.1m∕min(280IPM)

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Figure 12

Metal transfer in experiment 4, WFS: 14m∕min(550IPM)

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Figure 13

Image sequence of a droplet’s life span. Conventional GMAW, WFS: 7.1m∕min(280IPM). The white line is tracking the same droplet.

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Figure 14

Image sequence of a droplet’s life span. DE-GMAW, WFS: 7.1m∕min(280IPM); Bypass current: 66A. The white line is tracking the same droplet.

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