Study on metal transfer modes and welding spatter characteristics of self-shielded flux cored wire

Liu, H.-Y.; Li, Z.-X.; Li, H.; Shi, Yu

doi:10.1179/174329308x380354

Cited by 19 publications

(4 citation statements)

References 9 publications

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“…For example, though the spatter issue occurs when the swing arc is introduced [23], it has not attracted the attention of researchers. As is well known, welding spattering can lead to problems such as low wire utilization, poor bead formation, poor mechanical performance of the obtained joints and an extensive post-cleaning process [24][25][26]. In the multi-layer and multi-pass WAAM process, the spatter on the deposited pass is extremely detrimental to the deposition process stability of the subsequent pass and eventually to the performance of the WAAM component.…”

Section: Introductionmentioning

confidence: 99%

Optimization of CMT Characteristic Parameters for Swing Arc Additive Manufacturing of AZ91 Magnesium Alloy Based on Process Stability Analysis

Zhang

Shen

et al. 2023

Materials

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The droplet transfer behavior and stability of the swing arc additive manufacturing process of AZ91 magnesium alloy based on the cold metal transfer (CMT) technique were studied by analyzing the electrical waveforms and high-speed droplet images as well as the forces on the droplet, and the Vilarinho regularity index for short-circuit transfer (IVSC) based on variation coefficients was used to characterize the stability of the swing arc deposition process. The effect of the CMT characteristic parameters on the process stability was investigated; then, the optimization of the CMT characteristic parameters was realized based on the process stability analysis. The results show that the arc shape changed during the swing arc deposition process; thus, a horizontal component of the arc force was generated, which significantly affected the stability of the droplet transition. The burn phase current I_sc_wait presented a linear function relation with IVSC, while the other three characteristic parameters, i.e., boost phase current I_boost, boost phase duration t_I_boost and short-circuiting current I_sc2, all had a quadratic correlation with IVSC. A relation model of the CMT characteristic parameters and IVSC was established based on the rotatable 3D central composite design; then, the optimization of the CMT characteristic parameters was realized using a multiple-response desirability function approach.

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Section: Introductionmentioning

confidence: 99%

Optimization of CMT Characteristic Parameters for Swing Arc Additive Manufacturing of AZ91 Magnesium Alloy Based on Process Stability Analysis

Zhang

Shen

et al. 2023

Materials

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“…Łabanowski et al used the gas metal arc (GMA) local dry welding method to make welded joints of duplex stainless steel, which proved that duplex stainless steel had a good underwater local dry welding property [22]. Liu et al researched the metal transfer behavior of self-shielded flux-cored wire and found that the metal transfer mode included bridging transfer, globular repelled transfer, and droplet transfer [23]. Guo et al observed the metal transfer process of underwater flux-cored wet welding using an X-ray transmission method, and found four fundamental metal transfer modes, namely, the globular repelled transfer mode, the surface tension transfer mode, the explosive short-circuit transfer mode, and the “submerged arc transfer mode” [24,25].…”

Section: Introductionmentioning

confidence: 99%

Control of Droplet Transition in Underwater Welding Using Pulsating Wire Feeding

Guo

Huang

et al. 2019

Materials

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Underwater wet welding technology is widely used. Because the stability of droplet transfer in underwater wet welding is poor, the feasibility of improving the droplet transfer mode has been discussed from various technical directions. In this work, the characteristics of pulsating wire feeding were studied in the pulsating wire feeding mode by investigating the effects of changing the pulsating frequency, the wire withdrawal speed, and the wire withdrawal quantity on the droplet transfer process and the welding quality. With the aim of improving weld forming and welding stability, the authors selected the coefficient of variation and the ratio of unstable droplet transfer as the indexes to evaluate the effect of droplet transfer control. The pulsating wire feeding process of underwater wet flux-cored wire was analyzed in depth, and the following conclusions were drawn: using the pulsating wire feeding mode and after comparing and analyzing the pulsed wire feeding process under the same frequency condition, the authors found that the forming and stability were better under the conditions of slower withdrawal speed and smaller withdrawal quantity. The short-circuit transition ratio decreased steadily with the increase of pulsating wire feeding frequency, the rejection transition ratio first rose and then decreased, and the splash ratio first decreased and then rose.

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“…The main modes of molten droplet transfer in FCAW-S are short-circuit enclosed slag transfer without explosion, short-circuit transfer with explosion, short-circuit swaying outward transfer, globular transfer, projected transfer, explosive transfer, 5 and bridging transfer without arc interruption. 6, 7 In CO 2 gas shielded metal arc welding, the short-circuit transfer is an excellent transfer mode for its process stability, lesser welding spatter and low heat input. However, during the short-circuit transfer process in FCAW-S, the liquid slag covers the surface of the molten droplet and the weld pool, which increases the difficulty of arc re-ignition.…”

Section: Introductionmentioning

confidence: 99%

“…With an increase in arc voltage, the ratio of short-circuit transfer with explosion and globular transfer increases. Yu et al 6 finds that the short-circuit and non-short-circuit enclosed slag transfer are the main transfer modes when arc voltage is lower. With an increase in arc voltage, the ratio of non-short-circuit enclosed slag transfer increases and the ratio of short-circuit enclosed slag transfer decreases.…”

Section: Introductionmentioning

confidence: 99%

Characteristics of short-circuit behaviour and its influencing factors in self-shielded flux-cored arc welding

Zhu

Fan

Liu

et al. 2016

Science and Technology of Welding and Joining

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The characteristics of short-circuit behaviour during the process of self-shielded flux-cored arc welding and its corresponding welding electric information are investigated by a synchronous acquisition system of high-speed images and welding electric information. The research results show that when the welding arc between the wire tip and the weld pool extinguishes, a short-circuit event occurs and its corresponding arc voltage is below ,10 V, which can be used to judge the occurrence of the short-circuit procedure. Meanwhile, the influence of welding process setting parameters on the short-circuit behaviour is explored in detail. The existence of liquid slag increases the difficulty of arc re-ignition, which makes it easy to produce weld defects. Therefore, the short-circuit procedure in self-shielded flux-cored arc welding should be avoided as much as possible.

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Study on metal transfer modes and welding spatter characteristics of self-shielded flux cored wire

Cited by 19 publications

References 9 publications

Optimization of CMT Characteristic Parameters for Swing Arc Additive Manufacturing of AZ91 Magnesium Alloy Based on Process Stability Analysis

Optimization of CMT Characteristic Parameters for Swing Arc Additive Manufacturing of AZ91 Magnesium Alloy Based on Process Stability Analysis

Control of Droplet Transition in Underwater Welding Using Pulsating Wire Feeding

Characteristics of short-circuit behaviour and its influencing factors in self-shielded flux-cored arc welding

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