Abstract
In intelligent manufacturing, an intelligent control method of welding process is an important process of intelligent welding manufacturing technology (IWMT). Metal transfer is a key factor to control the welding process. Metal transfer and droplet spreading are of vital importance for welding formation. A new theoretical model of cold metal transfer (CMT) in short-circuit transfer mode is proposed in this paper. In this model, the CMT welding process is regarded as a continuous process of arc heating, mass transfer, short-circuit, and spreading, and the relations between these processes are analyzed. The calculation equations used by the model can analyze the welding formation clearly and simplify the complex welding process into continuous physical behavior. The predicted welding width shows good agreement with the measurement results. The mechanism of increased welding width is also comprehensively analyzed. Results have a certain guiding effect on aluminum alloy welding process control.
Highlights
IntroductionA weld controller is a typical system of the intelligent welding manufacturing system [1]
In intelligent manufacturing, a weld controller is a typical system of the intelligent welding manufacturing system [1]
Based on the model of the welding geometry, the cold metal transfer (CMT) welding experiments were carried out, and results were recorded by a highspeed camera. e diagram of experimental equipment is shown in Figure 1. e experimental data were compared with the model to analyze the effect of droplet transfer on the increase in the melt width
Summary
A weld controller is a typical system of the intelligent welding manufacturing system [1]. Intelligent control of welding dynamic process is one of main problems of intelligent welding technology. E short-circuit transfer in the metal transition is controlled through traditional MIG (metal inert gas)/MAG (metal active gas) welding to control the heat input and reduce the welding defects. Cold metal transfer (CMT) is an improvement of short-circuit transfer in GMAW (gas-metal arc welding) process, which has the characteristics of low splash and lowheat input. Lei et al [4] welded a 1 mm thick AA6061-T6 by using three welding arc modes of standard, pulsed, and CMT. Ey found that CMT arc mode produced the fewest welding defects. Ese studies confirm that CMT is superior to MIG/MAG in thin-plate welding and dissimilar metal welding. CMT can effectively control the heat affected zone (HAZ) and enhance the weldability of thin metal plates and dissimilar metals
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