Stabilization of the process of mechanized pulsed-arc welding
DOI:
https://doi.org/10.32347/tit2021.42.0202Keywords:
mechanized arc welding in shielding gases, arc stability, controlled transfer, current source, inductive resistance, short-circuit current rise rateAbstract
The main disadvantage of the mechanized arc welding process in shielding gases with short circuits is the spatter during melting of the electrode metal and its transfer to the weld pool, which affects the productivity of the process, reducing it. Its elimination is possible through the implementation of the controlled transfer of molten electrode metal into the weld pool. The implementation of such a transfer and the control of the processes that take place in the arc gap to a large extent determine the conditions for the qualitative formation of the deposited metal, the stability of the process, the magnitude of the loss of electrode metal and the manufacturability of the processes of arc welding in shielding gases. At the present stage of development of welding technologies, controlled transfer of electrode metal is possible due to the pulsed nature of arc burning. In this case, one of the main methods for increasing the efficiency of the process is to limit the maximum value of the short circuit current by increasing the inductive resistance of the welding circuit.
The research aimed to determine the effect of the rate of rising of the welding current during a short circuit on the stability of the welding arc. It was found that an increase in the current growth rate, starting from 1.23 kA/s to 50 kA/ s, leads to a decrease in the average duration of short circuits by at least 10 times. At the same time, the average frequency of short circuits increases by more than 2 times, from 36...38 s-1 to 80...86 s-1. The reason for this is the increase in the values of the electrodynamics’ Lorentz force, the action of which leads to the compression of the liquid metal bridge of the drop (pinch effect) due to an increase in the short circuit current. At the same time, there is a violation of the stability of the pulse process, and this is reflected in an increase in the average frequency of arc breaks by more than 30 times from 0.33 s-1 to 10 s-1. An increase in the energy parameters of the welding process led to a decrease in the average frequency of short circuits (2...3 times) and their average duration (2 times). The reason for this should be considered a change in the type of transfer of liquid metal – the welding process with short circuits has turned into a mixed process in which, along with short circuits, a droplet transfer of electrode metal is observed.
References
Potap'yevskiy A.G., Sarayev Yu.N., China-khov D.A., 2012. Svarka staley v zashchitnykh gazakh plavyashchimsya elektrodom. Tekhnika i tekhnologiya bu-dushchego. Tomsk, 208 (in Russian).
Sarayev Yu.N., Lunov A.G., Semenchuk V.M. etc., 2019. Kineticheskiye osobennosti teplomassoperenosa v usloviyakh svarki i naplavki. Izvestiya vysshikh uchebnyy zavedeniy. Fizika, Vol.62, 34-40 (in Rus-sian).
Paton B.Ye., Dudko D.A., Sidoruk B.C., 1988. Sostoyaniye i perspektivy razvitiya el-ektricheskoy svarki plavleniyem s mod-ulyatsiyey parametrov rezhima. Impul'snye protsessy svarki: Sb. nauch. Tr. Kiyv, IES im. E.O.Patona, 5-11 (in Russian).
Chao Chen, Sanbao Lin, Chenglei Fan etc., 2018. Feasibility analysis of pulsed ultra-sonic for controlling the GMAW process and weld appearance. The International Journal of Advanced Manufacturing Tech-nology, Vol.97, 3619-3624.
Kaiyuan Wu, Tong Yin, Nian Ding etc., 2018. Effect of phase on the behaviour of metal transfer in double-wire pulsed GMAW. The International Journal of Advanced Manufacturing Technology, V.93, 3777-3789.
Zhang Shuai, Cheng Fangjie, Di Xinjie etc., 2016. Study on arc characteristics and behaviour of metal transfer in pulse current flux-cored arc welding of mild steel. China Welding, No.4, 42-51.
Mezrag B., Deschaux-Beaume F., Bena-chour M., 2015. Control of mass and heat transfer for steel/aluminium joining using Cold Metal Transfer process. Science and Technology of Welding and Joining, Vol.20, 189-198.
Lebedev Vladimir, Reisgen Uwe, Lendiel Ivan, 2016. Study of technological opportunities of GMA welding and surfacing with pulse electrode wire feed. Welding in the World, Vol.60, 525-533.
Panga Jie, Hua Shengsun, Shena Junqi etc., 2016. Arc characteristics and metal transfer behavior of CMT + P welding process. Journal of Materials Processing Tech-nology, Vol. 238, 212–217.
Kamal Pal, Surjya K. Pal, 2011. Effect of Pulse Parameters on Weld Quality in Pulsed Gas Metal Arc Welding: A Review. Journal of Materials Engineering and Performance, Vol.20, 918-931.
Praveen P., Yarlagadda P., Kangb M.J., 2005. Advancements in pulse gas metal arc welding. Journal of Materials Processing Technology, Vol.164-165, 1113-1119.
DeRuntz, B.D., 2001. Surface Tension Transfer welding in manufacturing. Selected Paper presented at the National Association of Industrial Technology Conference, Detroit Michigan, 20-26.
Dos Santos Emanuel B. F., Pistor Rob, Gerlich Adrian P., 2017. Pulse profile and metal transfer in pulsed gas metal arc weld-ing – droplet formation, detachment and velocity. Science and Technology of Welding and Joining, Vol.22, 627-641.
Agrawal Banshi Prasad, Kumar Rajeev, 2016. Challenges in Application of Pulse Current Gas Metal Arc Welding Process for Preparation of Weld Joint with Superior Quality. International Journal of Engineering Research & Technology, Vol.5, 319-327.
Ghosh P.K., 2017. Concept of Pulse Current Gas Metal Arc Welding Process. Pulse Current Gas Metal Arc Welding: Characteristics, Control and Applications, 31-45.
Mainak Sen, Manidipto Mukherjee, San-tosh Kumar Singh, 2018. Effect of double-pulsed gas metal arc welding (DP-GMAW) process variables on microstructural constituents and hardness of low carbon steel weld deposits. Journal of Manufacturing Processes, Vol.31, 424-439.
Saraev Y.N., Lunev A.G., Semenchuk V.M. etc., 2019. Enhancing an arc welding technology by the methods of adaptive pulsed control of energetic parameters. IOP Conf. Series: Materials Science and Engineering, Vol.681 (2019) doi:10.1088/1757-899X/681/1/012038.
Zhao Yangyang, Chung Hyun, 2018. In-fluence of power source dynamics on metal and heat transfer behaviors in pulsed gas metal arc welding. International Journal of Heat and Mass Transfer, Vol.121, 887-899.
Pirumov A.Ye., Skachkov I.O., Maksimov S.Yu. etc., 2007. Spetsializirovannaya informatsionno-izmeritel'naya sistema dlya monitoringa protsessa svarki. Avtomatich-eskaya svarka, 8, 41-43 (in Russian).
Vladimirov A.V., Khabuzov V.A., Lebe-dev V.A. etc., 2011. Universal'nyy isto-chnik pitaniya dlya elektrodugovoy svarki i plazmennoy rezki na osnove tsifrovogo sin-teza tekhnologicheskogo protsessa. Avto-maticheskaya svarka, 1, 41-46 (in Russian).
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2021 Sergey Maksimov, Anatoly Gavrilyuk, Denys Krazhanovskyi
This work is licensed under a Creative Commons Attribution 4.0 International License.
Our journal abides by the CREATIVE COMMONS copyright rights and permissions for open access journals.
Authors, who are published in this journal, agree to the following conditions:
1. The authors reserve the right to authorship of the work and pass the first publication right of this work to the journal under the terms of a Creative Commons Attribution License, which allows others to freely distribute the published research with the obligatory reference to the authors of the original work and the first publication of the work in this journal.
2. The authors have the right to conclude separate supplement agreements that relate to non-exclusive work distribution in the form in which it has been published by the journal (for example, to upload the work to the online storage of the journal or publish it as part of a monograph), provided that the reference to the first publication of the work in this journal is included.
