Three-dimensional modelling of arc behaviour and gas shield quality in tandem gas–metal arc welding using anti-phase pulse synchronization

Schnick, Michael; Wilhelm, G; Lohse, Martin; Füssel, Uwe; Murphy, Anthony B.

doi:10.1088/0022-3727/44/18/185205

Cited by 40 publications

(9 citation statements)

References 29 publications

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“…Though the model could be tested to be accurate enough in practice, it cannot consider more elements in reality and outputs were so limited, and other more characteristics were also required to be obtained. Schnick et al [30] developed a transient three-dimensional model of an anti-phase-synchronized tandem GMAW process using a professional software package ANSYS CFX to explore the arc behavior and gas quality during the process. This work modified the standard equations of computational fluid dynamic to take into account the electromagnetic and radiative phenomena that occur in thermal plasmas, and other relative equations.…”

Section: Numerical Simulation Of the Double-wire Gmaw Processmentioning

confidence: 99%

“…This work modified the standard equations of computational fluid dynamic to take into account the electromagnetic and radiative phenomena that occur in thermal plasmas, and other relative equations. The model used a mirror-symmetric geometry of the torch, parent and the fluid region (arc plasma), as shown in Figure .3 [30].…”

Section: Numerical Simulation Of the Double-wire Gmaw Processmentioning

confidence: 99%

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Review of the Recent Trends of Process Monitoring and Control for Double- Wire GMAW Process

Zhou

Yao

2019

IEEE Access

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Recently, double-wire gas metal arc welding (GMAW) process is more and more prevalently employed in industrial applications and attracted many academic researches. This paper reviewed the recent trends of researches and applications of this process. Three main aspects were included in this paper. The first was the operational process analysis of the process, and the reviewing work was divided into two catalogues: twin-wire GMAW process and tandem GMAW process, which were two main energy delivery and control formations of the process. This part focused on some negative phenomena, such as arc interruption, during the welding process and their effects on the products quality and process stability. Some works about using different current waveforms combinations and their effects on the welding process were discussed. Also, the works of numerical simulation for this process were mentioned in this part. The second part was about process stability monitoring, and corresponding works focused on establishing quantitative process stability estimation model. The last was the improvement of process control method, and the works mainly focused on the adjustment and modulation of the current waveforms, in order to eliminate negative phenomena, improve the process stability and obtain the products with high quality. Finally, some suggestions about future works were presented. This paper can provide references and enlightens for current academic researches or actual industrial applications in the double-wire GMAW process relative areas.INDEX TERMS Double-wire GMAW process, arc interruption, process stability, current waveform.

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Section: Numerical Simulation Of the Double-wire Gmaw Processmentioning

confidence: 99%

Section: Numerical Simulation Of the Double-wire Gmaw Processmentioning

confidence: 99%

Review of the Recent Trends of Process Monitoring and Control for Double- Wire GMAW Process

Zhou

Yao

2019

IEEE Access

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“…In the almost-in-phase case, the time the trailing arc remains with intense deflection and low resistance to extinction is reduced; at the same time as the trailing arc resistance to extinction (interrup tion) is increased by raising its current level, its deflection is reduced. According to Schnick et al, minimizing arc deflection is crucial for efficient shielding of the welding region (arcs and welding pool) [11]. Again considering to the arc deflection model, an ideal situation, not tested in practice due to limitations in the control of the power sources, would be achieved for an in-phase situation, in which the trailing arc deflection would be kept at a low level all the time.…”

Section: Considerations On Arc Interruptions In Tandem Pulsed Gmawmentioning

confidence: 99%

“…Arc instabilities (abnormal arc voltages and interruptions) in Tandem Pulsed GMAW, also seem to play an important role in the introduction of air contaminations into the gas shield. Accord ing to a three-dimensional model of the Tandem GMAW arc welding process proposed by Schnick et al, the deflection (kink ing) of the arc in the base-current phase is particularly responsible for high levels of air contamination in the process region between the arcs and the hot regions of the workpiece, which might lead to weld seam imperfections such as porosity [11], Their model also demonstrates a strong deflection of the arcs during their basecurrent phases [11].…”

Section: Introductionmentioning

confidence: 99%

Arc Interruptions in Tandem Pulsed Gas Metal Arc Welding

Reis

Souza

Filho

2015

Journal of Manufacturing Science and Engineering

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In addition to electromagnetic attraction between the arcs in Tandem Pulsed gas metal arc welding (GMAW), arc interruptions, mostly in the trailing arc at low mean current levels, may also occur, which is a phenomenon not widely discussed in the welding field. These arc interruptions must be avoided, since they also represent interruptions in metal fusion and deposition during the welding process, leading to lack of fusion!penetration and/or deposition flaws, adding cost for repairing operations. To improve the under standing on arc interruptions in Tandem Pulsed GMAW and how the current pulsing syn chronism between the arcs relates to this phenomenon, this work proposes to evaluate the influence of parameters of adjacent arcs (Tandem Pulsed GMAW) and also of a single arc (GTAW-gas tungsten arc welding), but similarly subjected to magnetic deflection, on the occurrence of arc interruptions!extinctions. High-speed filming was used to help understand the interruption!extinction mechanism. In the case of Tandem Pulsed GMAW, the pulses of current of the leading and trailing arcs need to be almost-in-phase to pre vent interruptions in the trailing arc. The distance of 10 mm between the adjacent arcs helped reduce the incidence of trailing arc interruptions, yet keeping a sound weld visual quality. In the case of GTAW, the higher the electrical current flowing through the arcs and the shorter their lengths, the more they resist to the extinction. The trailing arc inter ruptions in Tandem Pulsed GMAW seem to be determined by the deflection and heat in this arc, and their prevention can be achieved by a balance between these two factors, which is reached by synchronized pulsing currents.

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“…Ogino et al [11] conducted a numerical investigation on the tandem TIG arc plasma and weld pool formation, and found that the distance between welding wires obviously influenced the arc shape, and the maximum arc pressure of the twoelectrode TIG arc was much lower than that of a singleelectrode TIG. Schnick et al [12] presented a transient three-dimensional model of an anti-phase-synchronized pulsed tandem gas-metal arc welding process, which was used to analyze arc interactions and their influences on the gas shield flow. The results demonstrated that strong arc deflection and kinking occurred, especially during the low-current phase of the pulse, which was in agreement with experimental observations.…”

Section: Introductionmentioning

confidence: 99%

Analysis of arc interference and welding stability in twin wire GMA welding

Hua

et al. 2015

Int J Adv Manuf Technol

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In order to better understand the arc interference behavior and welding stability in twin wire GMA welding, the synchronous acquisition system has been established to acquire instantaneous information of electric signals, arc profile, and droplet transfer including dynamic arc length variation. The results showed that after Trailing arc (T-arc) was added to the Leading arc (L-arc) in a stable welding process, the current of L-arc decreased and the voltage kept constant. The stable globular transfer of L-arc was destroyed and deflected, turned into spray transfer due to the effect of Tarc. Compared to the single wire welding, the arc length of L-arc increased and the welding operating point changed in twin wire welding.

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Three-dimensional modelling of arc behaviour and gas shield quality in tandem gas–metal arc welding using anti-phase pulse synchronization

Cited by 40 publications

References 29 publications

Review of the Recent Trends of Process Monitoring and Control for Double- Wire GMAW Process

Review of the Recent Trends of Process Monitoring and Control for Double- Wire GMAW Process

Arc Interruptions in Tandem Pulsed Gas Metal Arc Welding

Analysis of arc interference and welding stability in twin wire GMA welding

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