0
Research Papers

Analysis and Improvement of Metal Transfer Behaviors in Consumable Double-Electrode GMAW Process

[+] Author and Article Information
Ming Zhu

State Key Laboratory of Gansu,
Advanced Non-Ferrous Metal Materials,
Lanzhou University of Technology,
Lanzhou 730000China
e-mail: zhumings@yeah.net

Yu Shi

State Key Laboratory of Gansu,
Advanced Non-Ferrous Metal Materials,
Lanzhou University of Technology,
Lanzhou 730000, China
e-mail: shiyu73@gmail.com

Ding Fan

State Key Laboratory of Gansu,
Advanced Non-Ferrous Metal Materials,
Lanzhou University of Technology,
Lanzhou 730000, China
e-mail: fanding@lut.cn

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received January 2, 2014; final manuscript received August 30, 2014; published online November 26, 2014. Assoc. Editor: Wayne Cai.

J. Manuf. Sci. Eng 137(1), 011010 (Feb 01, 2015) (5 pages) Paper No: MANU-14-1006; doi: 10.1115/1.4028636 History: Received January 02, 2014; Revised August 30, 2014; Online November 26, 2014

Consumable double-electrode gas metal arc welding (consumable DE-GMAW) is the efficient improvement of DE-GMAW. Due to the variety of coupled arc and metal transfer behaviors, this paper applies static force balance theory to analyze the changes in the forces acting on the main and bypass droplets separately. For main torch, the bypass arc changes the forces affecting on the main droplet, and the main metal transfer becomes more desirable. For bypass torch, with direct current electrode negative (DCEN) polarity, the volume of droplet is big and not easily transfers to the weld pool. In order to improve the bypass metal transfer, a method has been proposed which adds CO2 to pure argon shielding gas to change the forces affecting on the bypass droplet. Then, the welding experiment is carried out to test the effectiveness of this method. It is found that bypass droplet transfers easily and the diameter of bypass droplet is decreased significantly. Also a good weld appearance is acquired.

FIGURES IN THIS ARTICLE
<>
Copyright © 2015 by ASME
Your Session has timed out. Please sign back in to continue.

References

David, S. A., and DebRoy, T., 1992, “Current Issues and Problems in Welding Science,” Science, 257(5069), pp. 497–502. [CrossRef] [PubMed]
Waszink, J. H., and Heuvel, G. P., 1982, “Heat Generation and Heat Flow in the Filler Metal in GMAW Welding,” Weld. J., 61(8), pp. 269–282.
Quinn, T. P., Szanto, M., Gilad, I., and Shai, I., 2005, “Coupled Arc and Droplet Model of GMAW,” Sci. Technol. Weld. Joining, 10(1), pp. 113–119. [CrossRef]
Wu, C. S., Zhong, L. M., and Gao, J. Q., 2009, “Visualization of Hump Formation in High-Speed Gas Metal Arc Welding,” Meas. Sci. Technol., 20(11), p. 115702. [CrossRef]
Nguyen, T. C., Weckman, D. C., Johnson, D. A., and Kerr, H. W., 2006, “High Speed Fusion Weld Bead Defects,” Sci. Technol. Weld. Joining, 11(6), pp. 618–633. [CrossRef]
Ueyama, T., Ohnawa, Y., Tanaka, M., and Nakata, K., 2007, “Occurrence of Arc Interaction in Tandem Plused Gas Metal Arc Welding,” Sci. Technol. Weld. Joining, 12(6), pp. 523–529. [CrossRef]
Lahnsteiner, R., 1992, “The T.I.M.E. Process—An Innovative MAG Welding Process,” Weld. Rev. Int., 2, pp. 17–20.
Heqing, Y., and Yao, Y., 2010, “Behavior of Charge Inertia Battery in Commutation Process of Variable-Polarity Welding Arc,” IEEE Trans. Plasma Sci., 38(8), pp. 2021–2026. [CrossRef]
Shao, Y., Wang, Z. Z., and Zhang, Y. M., 2011, “Monitoring of Liquid Droplets in Laser-Enhanced GMAW,” Int. J. Adv. Manuf. Technol., 57(1–4), pp. 203–214. [CrossRef]
Campana, G., Fortunato, A., Ascari, A., Tani, G., and Tomesani, L., 2007, “The Influence of Arc Transfer Mode in Hybrid Laser-Mig Welding,” J. Mater. Process. Technol., 191(1–3), pp. 111–113. [CrossRef]
Zhang, Y. M., Jiang, M., and Lu, W., 2004, “Double Electrodes Improve GMAW Heat Input Control,” Weld. J., 83(11), pp. 39–41.
Li, K. H., Chen, J. S., and Zhang, Y. M., 2007, “Double-Electrode GMAW Process and Control,” Weld. J., 86(8), pp. 231–237.
Li, K. H., and Zhang, Y. M., 2008, “Consumable Double-Electrode GMAW Part 1: The Process,” Weld. J., 87(1), pp. 11–17.
Yu, S.,Rihong, H., and Jiankang, H., 2014, “Numerical and Experimental Study of Temperature Field for Double Electrode Gas Metal Arc Welding,” ASME J. Manuf. Sci. Eng., 136(2), p. 02450201. [CrossRef]
Yu, S., Ming, Z., and Zhang, Y. M., 2012, “Study on Control System for High Efficiency Double-Electrode MIG Welding,” Trans. China Weld., 33(3), pp. 17–20.
Li, K. H., Chen, J. S., and Zhang, Y. M., 2007, “Double-Electrode GMAW Process and Control,” Weld. J., 86(7), pp. 231–237.
Li, K. H., and Zhang, Y. M., 2008, “Consumable Double-Electrode GMAW Part II: Monitoring, Modeling, and Control,” Weld. J., 87(2), pp. 44–50. [CrossRef]
Ming, Z., Yu, S., and Ding, F., 2012, “Simulation and Control of Consumable DE-GMAW Process,” Chin. J. Mech. Eng., 48(10), pp. 45–49. [CrossRef]
Li, K. H., and Zhang, Y. M., 2007, “Metal Transfer in Double-Electrode Gas Metal Arc Welding,” ASME J. Manuf. Sci. and Engineering, 129(6), pp. 991–999. [CrossRef]
Yu, S., Liu, Y., and Johnson, M., 2008, “Analysis of Metal Transfer and Correlated Influences in Dual-Bypass GMAW of Aluminum,” Weld. J., 87(9), pp. 229–236.

Figures

Grahic Jump Location
Fig. 1

Principle of consumable DE-GMAW

Grahic Jump Location
Fig. 2

Experiment system for consumable DE-GMAW

Grahic Jump Location
Fig. 3

Metal transfer and arc behaviors with pure argon shield: (a) main and bypass metal transfer behaviors (b) metal transfer and arc behaviors in 0.1 s

Grahic Jump Location
Fig. 4

Major forces acting on the main droplet in consumable DE-GMAW process

Grahic Jump Location
Fig. 5

Major forces acting on the bypass droplet in consumable DE-GMAW process

Grahic Jump Location
Fig. 6

Bypass metal transfer with 80%Ar + 20%CO2 shield: (a) main and bypass metal transfer behaviors (b) metal transfer and arc behaviors in 0.1 s, and (c) weld appearance

Grahic Jump Location
Fig. 7

Diameter of bypass droplet with pure Ar shield or 80%Ar + 20%CO2 shield

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In