Development of a plasma MIG welding system for aluminium

Ono, Kohei; Liu, Zhongjie; Era, Tesuo; Uezono, Toshiro; Ueyama, Tomoyuki; Tanaka, Manabu; Nakata, Kohei

doi:10.1080/09507110902836945

Cited by 32 publications

(14 citation statements)

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“…The droplet falls from the wire, accelerated by gravity, and flattens upon impact with the substrate. Ono et al (2009) proposed a coaxial plasma-assisted MIG welding process to improve deposited beads and reduce spatter and fume generation, as shown in Figure 8B. This hybriddeposition process is being implemented now in Additive Manufacturing (AM) to produce fully functional metallic objects.…”

Section: Metal Inert Gas-tungsten Inert Gas/ Plasma Hybrid-depositionmentioning

confidence: 99%

Hybridization in wire arc additive manufacturing

2022

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Wire Arc Additive Manufacturing (WAAM) can produce a near-net shape of an object within a short period due to its capability of high deposition rate compared with other metal Additive Manufacturing (AM) processes. The recent developments in the WAAM have increased its efficiency and cost-effectiveness in producing viable products. However, poor surface quality, porosities, residual stresses, distortions, and anisotropic mechanical properties are a few inherent challenges still associated with the WAAM, which necessitates the hybridization of this process. Hybrid-WAAM is a synergic integration of one or more deposition processes, manufacturing processes, layering strategies, raw stock materials, and machine tool kinematics that are fully coupled and affect part quality, functionality, and process performance. This paper comprehensively reviews different levels of hybridization in the WAAM to eliminate its associated challenges. These levels of hybridizations are classified into five categories: hybrid-deposition processes, hybrid-manufacturing processes, hybrid-layering strategies, hybrid-machine tools, and hybrid-raw stock. Furthermore, these levels of hybridization are mapped to eliminate the associated defects/challenges in the WAAM, which will help the readers select an appropriate level of hybridization.

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Section: Metal Inert Gas-tungsten Inert Gas/ Plasma Hybrid-depositionmentioning

confidence: 99%

Hybridization in wire arc additive manufacturing

2022

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“…Figure 1 shows an example of arc and plasma appearance. The plasma enables to the flexible control the arc shape through the inward Lorenz force produced by the plasma current and self-magnetic field, stabilizing the arc and metal transfer process and minimizing the spatter and fume formation [5]. Furthermore, the plasma with low energy density and large volume can uniformly preheat the base metal surface to a large extent with low heat flux, making it possible to form a high wettability bead [6].…”

Section: Introductionmentioning

confidence: 99%

Numerical Analysis of Metal Transfer Process in Plasma MIG Welding

Tashiro

Mamat

Murphy

et al. 2022

Metals

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In plasma MIG welding, inert gas introduced from the torch nozzle is ionized in the upstream region of the MIG arc, which is termed “plasma”. This study aims to clarify the effect of the plasma on the metal-transfer process in the plasma MIG welding through numerical analysis. As a result, the plasma with a temperature of approximately 10,000 K was found to be formed around the wire tip. The MIG arc temperature around the wire tip was 11,000 K at the maximum, which was lower than that of the conventional MIG welding by approximately 1000 K. This difference was caused by the decreased current density around the wire tip due to the influence of the plasma. The droplet temperature was also decreased by 400 K due to this lower current density. The amount of the metal vapor evaporated from the droplet was decreased compared to that of the conventional MIG welding due to the lower droplet temperature. This might lead to a decrease in fume formation generally known in the plasma MIG welding. In the conventional MIG welding, the arc attachment was concentrated around the wire tip, leading to a higher current density. However, in the plasma MIG welding, the plasma transported to the surrounding of the wire tip increases the electric conductivity in that region, due to the influence of the metal vapor mixture. This leads to the dispersion of the arc attachment toward the wire root. Consequently, the current density in the plasma MIG welding was found to decrease compared with that of the conventional MIG welding. The lower current density in plasma MIG welding decreases the Lorenz force acting on the wire neck, thus delaying droplet detachment to make the droplet diameter larger and the metal transfer frequency smaller. The latter was about 20 % of that in the conventional MIG welding.

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Section: Introductionmentioning

confidence: 99%

“…The development of plasma MIG welding is the hybrid welding process that realizes the plasma welding and MIG welding in a single torch [8]. This is a promising technology that utilizes the merits of plasma arc and MIG welding processes [8]. A recent study on plasma MIG has shown that the total heat input into base metal can be controlled through reduction of metal droplet temperature [9].…”

Section: Introductionmentioning

confidence: 99%

Observation of Microstructure and Mechanical Properties in Heat Affected Zone of As-Welded Carbon Steel by Using Plasma MIG Welding Process

Mamat

Sidek

Afandi

et al. 2022

Metals

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Plasma MIG welding is a hybrid welding process that combines two welding methods of conventional metal inert gas (MIG) welding with plasma arc welding. This study investigates the effect of plasma and plasma current values on the microstructure and microhardness properties of welded carbon steel plates. It was found that utilization of the plasma has resulted in a refined microstructure in the heat affected zones (HAZ), and a decrease in microhardness values as compared to conventional MIG welds. This potentially increases the ductility of the plasma MIG weldments. Furthermore, decreasing the plasma currents would result in the decrease of microhardness and grain sizes, thus further increasing the ductility of the welds.

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Development of a plasma MIG welding system for aluminium

Cited by 32 publications

References 0 publications

Hybridization in wire arc additive manufacturing

Hybridization in wire arc additive manufacturing

Numerical Analysis of Metal Transfer Process in Plasma MIG Welding

Observation of Microstructure and Mechanical Properties in Heat Affected Zone of As-Welded Carbon Steel by Using Plasma MIG Welding Process

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