Development of a highly productive GMAW hot wire process using a two-dimensional arc deflection

Spaniol, E.; Trautmann, M.; Ungethüm, T.; Hertel, M.; Füssel, Uwe; Henckell, Philipp; Bergmann, Jean Pierre

doi:10.1007/s40194-020-00880-9

Cited by 13 publications

(6 citation statements)

References 10 publications

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“…Based on the research conducted by the authors on the use of a magnetic arc de ection to increase productivity in GMAW hot wire welding, the potential of such a process for highly productive joint welding was demonstrated [31]. These investigations showed that 8 mm plates of 1.0045 with a Y-seam preparation and a web of 2 mm could not be welded without backing.…”

Section: Joint Welding 8 MM Sheetsmentioning

confidence: 99%

Joint welding of mild steel using a GMAW hot-wire process

Ungethüm,

Schilling,

Spaniol

et al. 2023

Preprint

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Due to the coupled filler material and energy supply in GMAW processes, these processes have limited productivity. To increase productivity and decrease heat input, a GMAW process can be combined with an auxiliary hot wire. In this paper a GMAW hot wire process with indirect resistive heating of the auxiliary wire (between two current nozzles) is used for joint welding of thick sheets (mild steel). In order to demonstrate the potential of the process for joint welding of mild steel plates (8 mm and 20 mm), test welds are carried out., Charpy impact and tensile specimens of the welds are produced to determine the mechanical properties of the joint. To further increase the understanding of the process, calorimetric measurements are conducted to quantify the energy input of the process. Based on the performed analyses, it is possible to demonstrate the potential of the process for joint welding and to show a possible competition to existing processes

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Section: Joint Welding 8 MM Sheetsmentioning

confidence: 99%

Joint welding of mild steel using a GMAW hot-wire process

Ungethüm,

Schilling,

Spaniol

et al. 2023

Preprint

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“…Because of its high specific strength, strong machinability, excellent corrosion resistance, and other performance advantages [1], 6061 aluminum alloy is widely used in modern essential equipment manufacturing sections, including aerospace [2,3], shipbuilding [4,5], transportation [6,7], etc. MIG (metal inert gas arc welding) technology is often applied in recent manufacturing methods of aluminum alloy complex structures of medium plate due to its high quality, high efficiency, and high flexibility [8]. However, molten pool depression and the thermal crack are prone to occur due to the difficulty of regulating the thermal force effect of the conventional process during the 6061 aluminum alloy welding [9].…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Investigation of the Thermal and Force Regulation Mechanism of Bypass Coupling Double-Sided Arc Welding Based on 6061 Aluminum Alloy

Zhang,

Wang,

Miao

et al. 2024

Coatings

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In this study, 6061 aluminum alloy was proposed for welding using bypass coupling double-sided arc welding (BCO-DASW) to further improve its welding quality and efficiency. To gain insight into the thermal and force regulation mechanism of the BCO-DASW of 6061 aluminum alloy, the dynamic effects of the high-temperature plasma inside the arc with various parameters were fully compared and investigated through the combined method of the physical experiment and the numerical simulation. The thermal flow field of the hybrid arc was analyzed numerically. Furthermore, its working adaptability and mechanical behaviors were studied experimentally. The results show that a single penetration of the 6 mm sheets can be achieved without visible defects when the center offset of the arcs is within 3 mm on both sides of the base metal during BCO-DASW. Through the thermal analysis, it was found that, compared with the MIG process, the introduction of the bypass arc lead to a temperature decrease at the bottom of the hybrid arc due to energy redistribution. Furthermore, through the kinetic analysis, it was found that not only could the level of arc pressure be reduced, but also the action range of the arc pressure could be regulated up to 4.6 mm. The thermal force regulation mechanism worked together to enhance the stability of the molten pool and achieves good joint strength during the BCO-DASW of 6061 aluminum alloy. This research not only has great significance in further improving the welding quality and efficiency of aluminum alloy, but also deeper understanding of the energy regulation mechanism during aluminum alloy welding.

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“…Welding processes that involve a hybridization of the hot-wire method (e.g., gas tungsten arc welding (GTAW), GMAW, submerged arc welding, laser welding) have been investigated and applied to improve productivity in fields beyond the construction machinery industry [11][12][13][14][15][16][17][18][19][20][21][22]. The welding phenomena and optimization of hot-wire feeding conditions have been investigated for the GTAW process [23].…”

Section: Introductionmentioning

confidence: 99%

Selection of Welding Conditions for Achieving Both a High Efficiency and Low Heat Input for Hot-Wire Gas Metal Arc Welding

Marumoto,

Fujinaga,

Takahashi

et al. 2024

JMMP

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This study presents a new gas metal arc welding (GMAW) technique that achieves both high efficiency and low heat input using a hybridization of the hot-wire method. The optimal combination of welding speed and welding current conditions was investigated using a fixed hot-wire feeding speed of 10 m/min on a butt joint with a V-shaped groove using 19 mm thick steel plates. Molten pool stability and defect formation were observed using high-speed imaging and cross-sectional observations. The power consumption and heat input were predicted prior to welding and measured in the experiments. The results indicate that a combination of a welding current of 350–500 A and welding speed of 0.3–0.7 m/min is optimal to avoid defect formation and molten metal precedence using three or four passes. The higher efficiency and lower heat input achieved by hot-wire GMAW results in a weld metal of adequate hardness, narrower heat-affected zone, smaller grain size at the fusion boundary, and lower power consumption than those obtained using tandem GMAW and high-current GMAW. Based on the experimental results, a single bevel groove, which is widely used in construction machinery welding joints, was welded using hot-wire GMAW, and we confirmed that the welding part could be welded in six passes, whereas eight passes were required with GMAW only.

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Development of a highly productive GMAW hot wire process using a two-dimensional arc deflection

Cited by 13 publications

References 10 publications

Joint welding of mild steel using a GMAW hot-wire process

Joint welding of mild steel using a GMAW hot-wire process

Experimental and Numerical Investigation of the Thermal and Force Regulation Mechanism of Bypass Coupling Double-Sided Arc Welding Based on 6061 Aluminum Alloy

Selection of Welding Conditions for Achieving Both a High Efficiency and Low Heat Input for Hot-Wire Gas Metal Arc Welding

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