Abstract
This article evaluates the performance of the cold-wire gas metal arc welding (CW-GMAW) process for narrow gap girth welding. The CW-GMAW process is characterized by the introduction of a continuously fed non-energized wire (cold-wire) into the electric arc/weld pool region. The cold-wire is melted by using the surplus heat available at the arc and molten metal at the weld pool. Narrow grooves 5 mm wide were prepared in 16 mm thick ASTM A131 grade A steel plates and filled using the CW-GMAW process. The feasibility of the process for narrow gap welding was assessed by analysing the joint cross section, microstructure and Vickers hardness. The mechanism by which the cold-wire prevents groove sidewall erosion is identified by using high speed imaging. It was found that for the CW-GMAW, the electric arc attaches to the cold-wire instead of the weld pool leading to a more stable arc, preventing the arc from attaching to the groove sidewall. The additional weld metal deposited by the cold wire, allowed complete filling of the groove with only three passes, demonstrating the productivity potential of the CW-GMAW process for narrow groove welding.
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