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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.

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References

Figures

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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

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Fig. 2

Experiment system for consumable DE-GMAW

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Fig. 1

Principle of consumable DE-GMAW

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Fig. 4

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

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Fig. 5

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

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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

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Fig. 7

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

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