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Double-Electrode GMAW Process and Control

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Double-Electrode GMAW Process and Control Li 8 07layout:Layout 1 8/6/07 5:00 PM Page 231 WELDING RESEARCH Double-Electrode GMAW Process and Control A novel welding process adds a GTAW torch to a conventional GMAW system to create a bypass arc for increasing melting current while controlling base current BY K. H. LI, J. S. CHEN, AND Y. M. ZHANG ABSTRACT. Double-electrode gas metal or arc length, is maintained constant. For GMAW, the double-electrode GMAW process arc welding (DE-GMAW) is a novel automatic and semiautomatic welding, the (Ref. 9) proposes a way to change this process that decouples the melting current productivity is mostly determined by the fundamental characteristic so that the into base metal current and bypass current travel speed provided that the welding melting rate can be freely increased. In a by adding a bypass torch to a conventional performance criterion is met, for example, previous preliminary study (Ref. 9), this GMAW system to establish a bypass arc. the cross-section area of the weld bead is change was realized by adding a plasma This makes it possible to increase the not changed with the travel speed. torch and a second power supply to a melting current while the base metal Obviously, a faster travel speed requires a conventional GMAW system. In this current can be controlled at a desired level. larger wire melting rate such that the study, the DE-GMAW process is Experiments have been done to find the melted metal is enough to form a longer implemented without the second power conditions that can assure a stable bypass weld bead in a unit time. Based on the supply. In addition, the plasma torch is arc is established/maintained between the work by Waszink and Heuvel (Ref. 1), the replaced by a gas tungsten arc welding welding wire and the bypass torch. To melting rate can be calculated by the torch which is more durable and cost control the base metal current at the following formula if the metal transfer is effective. desired level, a group of power resistors is in spray mode, i.e., the melting current is added in the bypass loop. The resistance of greater than 250 A for mild steels. Principles of DE-GMAW the power resistor group is adjusted real- 2 time by changing the combination of the −−13 IL 6 m =×51.. 10 +× 22 10 I A DE-GMAW system (Fig. 1) is resistors, and the change in the resistance S (1) . formed in this study by adding a results in a change in the bypass current where m (kg/s) is the melting rate, I (A) is nonconsumable tungsten electrode to and thus a change in the base metal the total melting current, L (m) is the wire decouple the melting current into base current. A model has been developed to extension, and S (m2) is the cross-sectional metal current and bypass current correlate the change of the resistance area of the wire. That means the melting needed to achieve the desired base metal current must be increased in order to II=+ I bm bp (2) current to the deviation of the base metal increase the melting rate. Unfortunately, where I (A) is the total current or melting current from its desired level. Experiments the melting current in conventional current, I (A) is the base metal current, demonstrated that the developed control GMAW is the same as the base metal bm I (A) is the bypass current. As can be system can adjust the bypass current in a current. Thus, a greater melting current bp seen in Fig. 1, the bypass current flows great range to maintain the base metal not only melts the wire faster, but also back to the power source through the current at the desired levels. increases the based metal heat input, bypass torch without going through the which contributes to increasing the weld base metal. As a result, the base metal Introduction pool, residual stress, and distortion. This current is no longer the same as the fundamental characteristic of conventional melting current and the fundamental Gas metal arc welding (GMAW) is a GMAW makes it difficult to increase the characteristics in conventional GMAW no major process for metals joining. deposition rate without imposing excessive heat longer apply. On the other hand, as is Conventional GMAW is normally used in to the base metal. illustrated later, the total melting current the direct current electrode positive While tandem GMAW (Refs. 2, 3), T.I.M.E is still determined by the wire feed speed polarity (DCEP), in which the wire is (Refs. 4, 5), and variable-polarity GMAW (Refs. and welding voltage as in conventional connected to the positive terminal of the 6–8) have successfully increased the melting rate GMAW. Hence, the bypass arc can change power source and the power source to certain degrees without changing this and reduce the base metal current without operates in the constant voltage (CV) fundamental characteristic of conventional changing the total melting current. mode. The reverse polarity contributes to The bypass loop in Fig. 1 includes an a stable arc, uniform metal transfer, and adjustable resistor. When this system is greater penetration. A CV power source KEYWORDS used, the user can choose the wire feed can adjust the welding current such that speed based on the deposition rate the wire melting rate is equal to the given Double-Electrode desired. The total current which melts the wire feed speed, and the welding voltage, GMAW wire will be dictated by the wire feed Base Metal Current speed and the arc voltage setting. When KEHAI LI, JINSONG CHEN, and YUMING Control the resistance of the adjustable resistor is ZHANG ([email protected]) are with Heat Input zero, the majority of the melting current Center for Manufacturing and Department of Welding Productivity Electrical and Computer Engineering, University would tend to flow through the bypass of Kentucky, Lexington, Ky. loop because the tungsten emits WELDING JOURNAL 231-s Li 8 07layout:Layout 1 8/6/07 5:00 PM Page 232 WELDING RESEARCH Fig. 1 — Proposed DE-GMAW system. Fig. 2 — Relationship between tungsten Fig. 3 — Controllable power resistor group. electrode, welding wire, and workpiece. electrons easier than the workpiece. To Shielding Gas for Bypass Electrode welding voltage for the GMAW power control the base metal current at the source is preset around 28–35 V desired level, the resistance of the To protect the tungsten electrode from correspondingly. adjustable resistor is feedback adjusted oxidizing, pure argon is recommended for using a current sensor that measures the shielding gas. Because of the action of Angle between Tungsten and base metal current — Fig. 1. electric field and arc radiation, the argon Welding Wire It is apparent that the heat absorbed by will be ionized. This ionized argon the tungsten and the power resistor is atmosphere further improves the stability Another parameter that determines wasted. However, this heat would be of the bypass arc. If the bypass current is the behavior and stability of the bypass arc applied to the base metal if the bypass higher than 150 A, a water-cooling system is the angle θ between the tungsten and loop is not applied as in conventional is required to protect the bypass torch. the welding wire, illustrated in Fig. 2. The GMAW so that the base metal is over- GMAW gun is placed at a normal work heated. That is, in conventional GMAW, Tungsten-to-Welding Wire Distance position. The angle θ can be adjusted by this heat is not only wasted, but also changing the position of the bypass torch. produces harm to the process. The horizontal distance from the Because the tungsten electrode needs to tungsten end to the welding wire end, d3 in point to the weld pool, the angle θ cannot Process Stability Fig. 2, is also an important parameter to be too large. Considering the size of the obtain a stable DE-GMAW process. It was bypass torch and the distance d1, the angle The presence of the bypass arc is the found that a distance in the range from 2 θ is limited to around 60 deg. fundamental characteristic of the DE- to 5 mm is optimal for achieving a stable GMAW process. A stable bypass arc bypass arc. A greater d3 will increase the Control System assures the DE-GMAW function. Hence, difficulty to start the bypass arc. A shorter the behavior and stability of the bypass arc d3 will expedite the melt-off of the The control system consisted of an must be studied and understood. For the tungsten electrode. adjustable power resistor group controlled novel DE-GMAW system demonstrated by IGBTs (isolated gate bipolar in Fig. 1, the behavior and stability of the Tungsten-to-Workpiece Distance transistors), two current sensors to detect bypass arc were determined by several the base metal current and bypass current, parameters discussed below. The distance between the tungsten and a PC to run the control program. The electrode and the workpiece, d2 in Fig. 2, controllable power resistor group shown in Bypass Electrode cannot be too large in order to start the Fig. 3 includes four individual parallel bypass arc. In DE-GMAW process, the power resistors, and each is controlled by In the proposed DE-GMAW process, GMAW gun feeds in the welding wire to an IGBT. When the IGBT is in “ON” there are two cathodes: one is the strike the main arc between the welding status, the corresponding power resistor workpiece, and the other is the bypass wire and the workpiece.
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