Abstract
The characteristics of weld bead formation and droplet transfer in pulsed gas metal arc weld (GMAW) with different arc lengths were studied by changing the base current time in this work. The results showed that it was easier to cause short circuits and spatters with a short arc. However, the deviation between the deepest point of penetration and the center of bead will be aggravated with the increase of arc length. In addition, more than 90% “one drop per pulse” (ODPP) transfer mode can be obtained when the pulse parameters were selected properly. However, the short arc trended to rise the proportion of “multiple drops per pulse” (MDPP), and the long arc trended towards increasing the proportion of “one drop per multiple pulses” (ODMP). Additionally, with the growth of the arc in the projected transfer zone, the penetration tended to become shallower because of the increase of arc heat dissipation, the fall of arc energy density, and droplet impact force. Overall, the strategy of choosing suitable arc length of pulsed GMAW was summarized: in order to obtain high-quality bead formation and weld joints, a shorter arc in the projected transfer zone was recommended.
Highlights
Arc welding technology is one of the most widely used welding methods in industrial production at present, having the advantages of energy concentration, high efficiency, easy realization of automation and wide range of material applicability [1,2]
In terms of whole tendency, the short trended to risetothe proportion of multiple drops per pulse” (MDPP), but the but long arc trended rise the proportion of one drop per multiple pulses” (ODMP)
Due to the suitable arc length in Test 4, the appropriate detaching arc force was matched with the one droplet per pulse” (ODPP) condition and the highest proportion of ODPP was observed
Summary
Arc welding technology is one of the most widely used welding methods in industrial production at present, having the advantages of energy concentration, high efficiency, easy realization of automation and wide range of material applicability [1,2]. Wu [15] put forward a six-parameter pulse waveform and obtained a mode of ODPP with lower heat input, proving the important influence of the droplet-detachment current and time on the droplet transfer. Compared with short circuiting transfer, the arc length could be adjusted, and no spatter welding seam could be obtained using pulsed current, leading to the advantages that the step of removing spatter on the base metal can be avoided and the manufacturing efficiency can be increased. The research results are helpful for optimizing the welding parameters, improving the quality of weld formation, and promoting the further application of pulsed GMAW in industrial automation production and robot welding field
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