Spatter Generation During Constant Voltage DC-AC Pulse Tandem Gas Metal Arc Welding Process

Abstract

To enhance productivity and provide high quality production material in a GMA welding process, weld quality, productivity and cost reduction affects the number of process variables. In addition, a reliable welding process and conditions must be implemented to reduce weld structure failure. In various industries the welding process mathematical model is not fully formulated for the process parameter and on the welding conditions, therefore only partial variables can be predicted. The research investigates the interaction between the welding parameters (welding speed, distance between electrodes, and flow rate of shielding gas) and bead geometry for predicting the weld bead geometry (bead width, bead height). Taguchi techniques are applied to bead shape to develope curve equation for predicting the optimized process parameters and quality characteristics by analyzing the S/N ratio. The experimental results and measured error is within the range of 10% presenting satisfactory accuracy. The curve equation was developed in such a way that you can predict the bead geometry of constructed machinery that can be used for making tandem welding process.

Droplet transfer and spatter generation in DC–AC pulse tandem gas metal arc welding

“…In AC-GMAW, optimisation of the pulse waveform is complicated because the number of control parameters is twice that of GMAW-P [22]; recently, fully digital controlled power sources with built-in parameter sets have been developed for AC-GMAW, and a reliable droplet transfer and arc length control have been reported [23, 24]. Stable drop transfer and arc formation have been confirmed for an asynchronous T-GMAW process with AC-GMAW introduced into the trailing process [25]. In GMAW-P, the peak current is higher than that in standard GMAW, and a stiffer arc is established.…”

Anticorrosion Performance of FCAW Cladding with Regard to the Influence of Heat Input

“…Spatter is one common welding defect that is generated during GMAW. In a recent work, Kang et al showed spatter can be minimized by utilizing proper inter-wire distance and range of current for leading and lagging electrode 5) . Flux cored arc welding is a special type gas metal arc welding process in which annular consumable electrode is filled by flux.…”