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research-article

Double Pulse Low-frequency Modulation for High-power Double-wire Pulsed MIG Welding

[+] Author and Article Information
Kaiyuan Wu

School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510640, China; Engineering Research Center for Special Welding Technology and Equipment of Guangdong Province, South China University of Technology, Guangzhou 510640, China
wuky@scut.edu.cn

Zhuoyong Liang

School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510640, China; Engineering Research Center for Special Welding Technology and Equipment of Guangdong Province, South China University of Technology, Guangzhou 510640, China
1964839474@qq.com

Tong Yin

School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510640, China; Engineering Research Center for Special Welding Technology and Equipment of Guangdong Province, South China University of Technology, Guangzhou 510640, China
scutwky2000@163.com

Zuwei He

School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510640, China; Engineering Research Center for Special Welding Technology and Equipment of Guangdong Province, South China University of Technology, Guangzhou 510640, China
45184525@qq.com

Min Zeng

School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510640, China; Engineering Research Center for Special Welding Technology and Equipment of Guangdong Province, South China University of Technology, Guangzhou 510640, China
fjlctt@163.com

1Corresponding author.

ASME doi:10.1115/1.4040319 History: Received August 02, 2017; Revised May 16, 2018

Abstract

A double pulse low-frequency modulation method was proposed to improve heat input control and enhance weld quality during high-power double-wire pulsed gas metal arc welding (GMAW). By constructing a mathematical model, relationships between parameters of double pulse low-frequency modulation and energy input were analyzed. A correction coefficient was added to overcome physical characteristics of charging and discharging in a welding circuit. Thus qualitative relationships between parameters of double pulse low-frequency modulation and energy input were described more accurately. Bead-on-plate welding experiments were conducted in a synchronous phase mode. A stable welding process was achieved and perfect weld bead shapes were acquired. Modulation frequency imposed a significant effect on both weld width and penetration, while modulation duty cycle had a significant effect on penetration and little effect on weld width. Modulation frequency significantly influenced refinement of grain size. Weak and strong pulses of low-frequency modulation improved heat input control, strengthened stirring action of double pulse on weld pool, and enhanced fluidity of molten metals, thereby contributing to optimization of weld quality.

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