Control of droplet transfer using a filler-wire in tandem arc welding

Abstract

In this paper, the tandem flux-cored arc welding process was enhanced to improve weld productivity. Additional filler-wire of opposite polarity was used to prevent deterioration of weld quality that occurred due to arc interaction at two electrodes. Droplet transfer is one of the main factors which determine the quality of the weldment. In the tandem process, it is difficult to control droplet transfer due to arc interaction. In the hybrid welding process developed for stabilising the molten pool, the arc interaction and droplet transfers of the two electrodes in the hybrid process were investigated according to the feeding location and applied current of the fillerwire. This presented a method for improving the penetration depth and bead appearance of the weldment.

Influence of high-frequency pulse on droplet transfer process and weld formation in double-wire median pulsed GMAW of aluminum alloy

“…Liu et al [10] studied the influence of torch configuration on arc interaction behavior in DW-GMAW and discovered that torch configuration affects the arc interaction behavior, consequently affecting the droplet transfer mode. Kim et al [11,12] used an opposite polarity welding wire to control the droplet transfer process in tandem GMAW, demonstrating that the welding wire at the central position effectively reduces the electromagnetic effect caused by the tandem electrodes, thereby reducing arc interference and droplet deflection.…”

Application of synchronized tandem welding to high-hardness armor steel

“…In contrast, tandem welding can achieve the desired bead width and penetration depth in a single pass [ 26 ]. Additionally, significant research aims to boost productivity by introducing extra filler metals [ 27 ]. In the context of HHA plates, the strength of the HAZ can diminish due to elevated heat input, necessitating a thorough analysis [ 28 ].…”

Monitoring of root gap change based on electrical signals of flux-cored arc welding using random convolution kernel transform

“…The welding process has been automated to increase productivity and improve weld quality in various manufacturing sectors, such as the automotive and shipbuilding industries [1,2]. Hence, automated welding machines, such as robots and auto-carriage machines, are widely employed [3][4][5]. However, their usage is limited to predetermined welding conditions.…”