Optimization of welding conditions for hot-wire GMAW with CO2 shielding on heavy-thick butt joint

Suwannatee, N.; Wonthaisong, Somchai; Yamamoto, Masayuki; Shinohara, Shinichiro; Phaoniam, Rittichai

doi:10.1007/s40194-021-01227-8

Cited by 14 publications

(11 citation statements)

References 14 publications

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“…However, at 54.15% HW, the molten pool front collapsed and flowed ahead of the arc position, causing the arc to occur at a lower position. This phenomenon, known as molten metal precedence, has been reported under excessive total deposition volume conditions [25,26]. Bead appearance at the 54.15% HW condition showed a humping bead, which is obvious evidence of molten metal precedence [24][25][26].…”

Section: Limitation Of Hot-wire Fractionmentioning

confidence: 59%

“…Optimization of the hotwire fraction was also studied by Wonthaisong et al [25] to achieve a single-V butt joint of a 20-mm thick steel plate with increased weld metal hardness. However, limitations of hot-wire technology have been identified, such as the potential for excessive deposition volume from the hot-wire and GMAW filler metals, resulting in imperfections such as irregular bead shape, incomplete fusion, and molten metal precedence [26].…”

Section: Introductionmentioning

confidence: 99%

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Optimization of hot-wire fraction for enhance quality in GMAW

Suwannatee,

Yamamoto,

Shinohara

2023

Weld World

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The combination of hot-wire insertion technology and gas metal arc welding (GMAW) is proposed to increase deposition rate and reduce power consumption. This study systematically investigated the effect of hot-wire fraction on weld metal properties. The results show that the compensatory deposition rate from hot-wire insertion provides a similar effective height compared with the rate from conventional GMAW, with a lower weld height/width ratio, lower power consumption, and improved mechanical properties. However, an excessive hot-wire fraction can lead to lack of fusion, and this value should be limited to no more than 44% of the total deposition rate. The relative GMAW and hotwire fractions were optimized to maximize total deposition volume while avoiding lack of fusion and providing sufficient penetration. With the optimized condition, hot-wire GMAW could be efficiently used to obtain similar deposition rates with lower power consumption and without sacrificing toughness properties. This proposed process offers a sustainable alternative development to conventional GMAW.

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Section: Limitation Of Hot-wire Fractionmentioning

confidence: 59%

Section: Introductionmentioning

confidence: 99%

Optimization of hot-wire fraction for enhance quality in GMAW

Suwannatee,

Yamamoto,

Shinohara

2023

Weld World

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“…Suwannatee et al further reported using a hot wire to weld 36-mm-thick K36E-TM steel plates in four layers without defects and high weld qualities (Ref. 14).…”

Section: Introductionmentioning

confidence: 99%

The GMAW Process Using a Two-Dimensional Arc Deflection with AC Hot Wires

SCHMIDT¹,

BERGMANN²,

SPANIOL³

et al. 2023

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Heat input in gas metal arc welding (GMAW) directly correlates with the applied current. As a result, welding irregularities, such as incomplete fusion and excessive penetration, increase and mechanical properties decrease. One way for adjusting heat input is to use hot wire technology. In this article, a two-dimensional arc deflection in GMAW was presented by simultaneous application of two alternating current (AC) hot wires. It is shown how the positioning of the hot wires and the signal characteristics of the current intensity influenced the deflection pattern and weld quality. It was found that the magnetic fields of the two hot wires overlapped due to the narrow opening between. Therefore, an increased one-dimensional deflection resulted. To obtain a two-dimensional deflection, it was necessary to shield the magnetic fields from each other by means of a ferritic material. By pulsing or phase shifting the current signals, individual deflection patterns were possible. The effect of arc deflection was visualized with highspeed recordings and metallographic investigations. Different deflection patterns were generated to adjust heat input and counteract weld irregularities. The use of hot wire technology allowed an increase in deposition rate by simultaneous improvement of weld quality.

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“…The high-speed brazing used a high-power diode laser with a hot-wire system for Joule heat a ller wire just below its melting point. The process enabled an e cient supply of ller materials [22][23][24], and it minimized the heat needed to melt the ller wire, reducing the heat input to the base materials. The diode laser could accurately control the beam shape and power to stably melt the ller wire while minimizing heating of the base materials.…”

Section: Introductionmentioning

confidence: 99%

Elucidation of dissimilar material joining phenomena on steel and aluminum alloy using hot-wire laser brazing

Ito,

Tomita,

Taniguchi

et al. 2023

Preprint

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When steels and aluminum alloys are joined by normal welding, brittle intermetallic compounds (IMC) are generated at the interface, which causes a decrease in joint strength. Dissimilar steel/aluminum alloy joints formed via hot-wire laser brazing can stably suppress IMCs, as elucidated by visualization during brazing and cross-sectional imaging of fabricated joints. In addition, the effects of various coatings on steel plates were investigated by comparing joint cross-sections and interfaces. Zn (galvanized, galvannealed) layers, flux, and a molten pool prevented direct laser-beam irradiation of the steel surfaces. A high brazing speed could enable a high cooling rate, creating a very low peak temperature of the steel and suppressing IMC formation. The galvanized Zn coating also prevented direct contact of the aluminum alloy with the steel surface. Thus, the galvanized steel suppressed IMC formation more than non-coated steel. Because a Fe-Zn alloy coating layer was a source of Fe for IMC formation, a thicker IMC was generated on galvannealed steel.

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Optimization of welding conditions for hot-wire GMAW with CO2 shielding on heavy-thick butt joint

Cited by 14 publications

References 14 publications

Optimization of hot-wire fraction for enhance quality in GMAW

Optimization of hot-wire fraction for enhance quality in GMAW

The GMAW Process Using a Two-Dimensional Arc Deflection with AC Hot Wires

Elucidation of dissimilar material joining phenomena on steel and aluminum alloy using hot-wire laser brazing

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