Evaporation phenomena of magnesium from droplet at welding wire tip in pulsed MIG arc welding of aluminium alloys

Wang, Jinbin; Nishimura, Hiroshi; Katayma, Seiji; Mizutani, Masami

doi:10.1179/1362171810y.0000000030

Cited by 16 publications

(15 citation statements)

References 34 publications

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“…As shown by numerical estimates [27], metal inside the drop is involved into eddy motion, caused by Marangoni effect and influence of electromagnetic forces. Intensive stirring of drop metal is also confirmed by experimental studies [28]. As a result, convective mechanism of heat transfer in drop metal prevails over the heat conductivity process.…”

supporting

confidence: 56%

“…Studying the dynamics of neck thinning and breaking at drop detachment, in particular formation of satellite drops, is of considerable interest, as well as physical processes running in the already detached drop [35]. In addition, hydrodynamic processes in the drop metal lead to emergence of convective diffusion of alloying elements [28]. Transport of alloying elements with a low boiling temperature, from fusion boundary to drop free surface, increases their evaporation intensity.…”

mentioning

confidence: 99%

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Methods of mathematical modelling of the processes of electrode metal drop formation and transfer in consumable electrode welding (Review

Semyonov¹,

Paton²

2014

The Paton Welding J.

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Processes of welding wire heating and melting, electrode metal drop formation and transfer in consumable electrode welding largely determine welding efficiency and quality. In its turn, the nature of metal melting and transfer with this welding process is determined by a large number of such physical phenomena as heat and mass transfer, gas(hydro)dynamics, electromagnetic processes, running in arc plasma, on the surface and in the volume of molten electrode metal-drop. This paper gives a review of currently available methods of theoretical investigation and mathematical modelling of the above processes, allowing prediction of such characteristics of electrode metal transfer as drop volume and shape, their thermal and gas-dynamic state, detachment frequency, etc. Advantages and disadvantages of the considered models are analyzed and main directions of their further development are outlined. 37 Ref.,11 Figures. K e y w o r d s : consumable electrode welding, mathematical modelling, electrode metal drop formationInterest to the problem of metal transfer in consumable electrode welding is due to a number of causes. It is known that formation of electrode metal drop can be accompanied by its overheating, leading to considerable loss of alloying elements contained in welding wire, bulk boiling and spattering of drop metal, closing of arc gap, etc. In addition, metal transfer mode essentially influences the processes running in the weld pool that, in its turn, determines weld formation. Ensuring directed metal transfer in welding in different positions is also important. Therefore, this work sets forth the known theoretical approaches and describes the available mathematical models, allowing prediction of the main characteristics of metal transfer at different technological parameters of consumable electrode welding.Methods of mathematical modelling of drop formation and electrode metal transfer in consumable electrode welding can be conditionally divided into two main groups (Figure 1). The first includes approaches, which enable prediction of just the individual characteristics of metal transfer process, such as drop size and detachment frequency. The main disadvantage of these models consists in that they do not allow determination of drop shape, or describing the phenomena of charge and energy transfer in molten electrode metal, which accompany the considered technological process. The first group includes such procedures as static force balance theory (SFBT) [1][2][3], pinch instability theory (PIT) [4][5][6], as well as dynamic force balance theory (DFBT) [7,8]. The second group includes the model of drop formation in terms of hydrostatic approximation [9-11], as well as models based on equations of motion of viscous incompressible liquid. In its turn, in the subgroup of dynamic models thin jet approximation can be singled out [12][13][14], as well as models based on total system of Navier-Stokes equations [15][16][17][18][19][20]. Let us consider the most widely accepted of the above methods.SFBT. This method is...

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confidence: 56%

mentioning

confidence: 99%

Methods of mathematical modelling of the processes of electrode metal drop formation and transfer in consumable electrode welding (Review

Semyonov¹,

Paton²

2014

The Paton Welding J.

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“…One of the important points of arc welding of aluminium alloys is the danger of burnout alloying elements of the wire and the base metal [15]. Thus, during pulsed MIG welding in argon at an increased current, the temperature of the electrode metal droplets grows (up to the temperatures of 2100−2600 K), which leads to an intensive burnout of magnesium in them (content of magnesium is 2−3 times decreased and more) [16]. Due to burnout magnesium, in the electrode metal droplets pores can be formed, which in the process of mass transfer get into the welding pool and can result in porosity of the welds.…”

Section: Scientific and Technicalmentioning

confidence: 99%

Hybrid welding of aluminium 1561 and 5083 ALLOYS USING Plasma-arc and consumable electrode arc (plasma-MIG)

Babych¹,

Korzhyk²,

Grynyuk³

et al. 2020

The Paton Welding J.

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“…Since the boiling point of magnesium is 1090 • C, the vaporization of magnesium will occur. In the study of Wang [12], the volume temperature of the aluminum alloy filler wire was measured when the peak current was 335 A during GMA welding, and it was about 1700-1730 K (1427-1457 • C), which caused the magnesium to vaporize. Studies on the deterioration of the mechanical properties caused by the vaporization of magnesium when welding aluminum alloys have been reported in the gas tungsten arc (GTA) welding process and the laser welding process, but studies of the GMA welding process have not been reported [13][14][15].…”

Section: Introductionmentioning

confidence: 99%

Mechanical Properties of Aluminum 5083 Alloy GMA Welds with Different Magnesium and Manganese Content of Filler Wires

Kim

Hwang

et al. 2021

Applied Sciences

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Gas metal arc welding of aluminum 5083 alloys was performed using three new welding wires with different magnesium and manganese contents and compared with commercial aluminum 5183 alloy filler wire. To investigate the effect of magnesium and manganese contents on the mechanical properties of welds, mechanical properties were evaluated through tensile strength, bending, and microhardness tests. In addition, the microstructure and chemical composition were analyzed to compare the differences between each weld. The tensile strengths of welds using aluminum alloy filler wires with a magnesium content of 7.33 wt.% (W1) and 6.38 wt.% (W2), respectively, were similar. The tensile strength and hardness of welds using wires with a similar magnesium content, but a different manganese content of 0.004 wt.% (W2) and 0.46 wt.% (W3), respectively, were higher in the wire with a high manganese content. Through various mechanical and microstructural property analyses, when the magnesium content of the filler wire was 6 wt.% or more, the manganese content, rather than the magnesium content, had a dominant effect on the strengthening of the weld.

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Evaporation phenomena of magnesium from droplet at welding wire tip in pulsed MIG arc welding of aluminium alloys

Cited by 16 publications

References 34 publications

Methods of mathematical modelling of the processes of electrode metal drop formation and transfer in consumable electrode welding (Review

Methods of mathematical modelling of the processes of electrode metal drop formation and transfer in consumable electrode welding (Review

Hybrid welding of aluminium 1561 and 5083 ALLOYS USING Plasma-arc and consumable electrode arc (plasma-MIG)

Mechanical Properties of Aluminum 5083 Alloy GMA Welds with Different Magnesium and Manganese Content of Filler Wires

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