Comparative Study of Droplet Transfer Modes on Appearance, Microstructure, and Mechanical Properties of Weld during Pulsed GMAW

Zhai, Peizhuo; Xue, Songbai; Wang, Jianhao; Tao, Yu; Chen, Weizhong; Chen, Tao; Ji, Shilei

doi:10.3390/met10050611

Cited by 14 publications

(5 citation statements)

References 30 publications

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“…The independent variables were wire feed speed (X1), welding speed (X2), and weld face rotation angle (X3). Table 2 presents the welding parameters selected for the pulsed GMAW metal transfer mode used in the welding trials [18]. As reported by Lázaro [18], these welding parameters resulted in weld beads with good appearance and quality in any position.…”

Section: Initial Parametersmentioning

confidence: 92%

Prediction of bead geometry on filling cavities in hydroelectric turbine blades by means of robotic welding

Plata

Carvalho

Flórez-Solano

2022

J. Phys.: Conf. Ser.

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This paper presents a methodology of mapping the bead geometry, deposited on a fillet like joint, as a function of the input parameters of the synergic pulsed gas metal arc welding process and the welding position, to allow the planning of repairing hydroelectric turbine runner blades by means of robotic welding. The challenges of automating the repair process; further, to choosing the best welding parameters, include the definition of the path that the robot must follow during the metal deposition, such that it is able to fill completely the damaged blade cavity, by means of producing overlapped layers from several individual weld beads. Thus, this research focused on developing statistical prediction models that could map the geometric variations of the weld bead section as function of the input parameters (wire feed speed, welding speed and bead face rotation angle). For this purpose, the bead section was approximated by a parallelogram whose height, width and inclination angle were considered as dependent variables. Several welding trials were carried out according to a central composite experimental design and three multiple regression models were obtained. Here, the physics is used to interpret the influence of the input parameters on the output results.

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Section: Initial Parametersmentioning

confidence: 92%

Prediction of bead geometry on filling cavities in hydroelectric turbine blades by means of robotic welding

Plata

Carvalho

Flórez-Solano

2022

J. Phys.: Conf. Ser.

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“…To overcome this problem, pulsing is generally applied during the GMAW. 27 The pulsed current in GMAW attributes to a controlled metal transfer in spray mode at a lower average current. 28 Due to pulsing, a defect-free weld joint with desired penetration is produced at lower heat inputs.…”

Section: Introductionmentioning

confidence: 99%

“…26 In addition, a stabilized arc with a negligible amount of spatters was witnessed in the pulsed GMAW. 27 Devakumaran et al 29 analyzed the influence of various types of inverter-based GMAW power sources (GMAW, P-GMAW, dual pulse-GMAW and modified short circuit-GMAW) at dynamic and static conditions while welding mild steel plates. The researcher observed that process parameters such as welding current, arc voltage and wire feed rate were directly correlated.…”

Section: Introductionmentioning

confidence: 99%

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Investigations on microstructural and mechanical properties of BSK 46 steel weldments

Sivateja

Asati

Vidyarthy

2023

Proceedings of the Institution of Mechanical Engineers, Part E:

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BSK 46 is a low alloy structural steel with excellent mechanical and corrosion properties and is widely used in many applications, including tipper bodies of heavy-duty trucks. Optimizing the welding parameters to reduce defects and improve productivity is critical for the users. The present work addresses optimizing the welding process parameters to improve productivity with adequate weld quality during the pulsed gas metal arc welding (P-GMAW) process. Three BSK 46 weldments (weld-1, weld-2 and weld-3) were fabricated by varying the root gap, root face, filler pass and heat input. The metallographic and mechanical characterization of P-GMAW weldments were done through microstructures, Vickers micro-hardness, transverse tensile strength, Charpy toughness and three-point bend test. Subsequently, a correlation has been developed between the microstructural features and mechanical properties of the weld joints. The hardness was found to be incremental in nature from the base metal to the fusion zone. Maximum hardness of 215.81 ± 10 HV was observed in the weld-3 fusion zone. Tensile test results reveal that weld-3 weldments exhibit a higher tensile strength of 547.48 ± 2 MPa than weld-1 (537.46 ± 7 MPa) and weld-2 (533.67 ± 9 MPa) weldments. Maximum impact toughness of 136.33 ± 14 J was observed in the weld-3 weldments. Post-bend testing showed no cracks on the weld surfaces, indicating defect-free weld joints with good ductility. It is observed that weld-3 showed relatively better mechanical properties than weld-1 and weld-2 in lesser welding time and lower welding cost

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“…Many robotic systems require a rotating axis to guide the wire, which limits their applicability [6]. However, in order to establish GMAW as an interesting alternative for the above technologies, the necessary initial objective is the detailed study of the strategies of torch movement [7] and the modes of metal transfer [8], to identify the most interesting types in each application [9], including the most recent modes, such as pulsed AC, which is discussed in this paper.…”

Section: Introductionmentioning

confidence: 99%

Effect of the Metal Transfer Mode on the Symmetry of Bead Geometry in WAAM Aluminum

Veiga

Suárez²,

Aldalur³

et al. 2021

Symmetry

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The symmetrical nature in the case of wall fabrication by wire arc additive manufacturing (WAAM) has been observed in the literature, but it has not been studied as a source of knowledge. This paper focuses on the comparative study of three drop transfer methods employing Gas Metal Arc Welding (GMAW) technology, one of the most reported for the manufacture of aluminum alloys. The transfer modes studied are the well-known pulsed GMAW, cold arc, and the newer pulsed AC. The novelty of the last transfer mode is the reversal of the polarity during the preparation phase of the substance for droplet deposition. This study compares the symmetry of zero beads to determine the best parameters and transfer modes for wire arc additive manufacturing of 5 series aluminum. The pulsed transfer modes show values of 0.6 for symmetry ratio, which makes them more interesting strategies than cold arc with a symmetry ratio of 0.5. Furthermore, the methodology proposed in this study can be extrapolated to other materials manufactured with this technology.

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Comparative Study of Droplet Transfer Modes on Appearance, Microstructure, and Mechanical Properties of Weld during Pulsed GMAW

Cited by 14 publications

References 30 publications

Prediction of bead geometry on filling cavities in hydroelectric turbine blades by means of robotic welding

Prediction of bead geometry on filling cavities in hydroelectric turbine blades by means of robotic welding

Investigations on microstructural and mechanical properties of BSK 46 steel weldments

Effect of the Metal Transfer Mode on the Symmetry of Bead Geometry in WAAM Aluminum

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