Abstract
This study performed welding on various welding positions in the flat, overhead, and vertical down positions using a pulsed gas metal arc welding (P-GMAW) process. Despite the same amount of heat input on various welding positions, the welding characteristics varied depending on the welding positions. The effect of gravity on the welding process determined the different formation of the weld bead, and the influence of molten pool behavior on various welding positions changed the microstructure in the weld metal. The current and voltage signals were synchronized with a high-speed camera using a data acquisition (DAQ) system. To induce the one pulse one drop (OPOD) process of metal transfer, the shielding gas was used 95% Ar+5% CO2. The microstructure of the weld metal was analyzed in relation to molten pool behavior.
Highlights
Kumar et al [1] and Kim et al [2] found that pulsed gas metal arc welding (P-GMAW) decreased the spatter and reduced the occurrence of incomplete fusion defects while providing a lower heat input and achieving high penetration
The P-GMAW process incorporated the benefits of axial spray transfer of one pulse one drop (OPOD) of GMAW, which improve the stability and quality of the welding process
The observation of the molten pool behavior captured the longitudinal direction with 5000 frames per second (FPS)
Summary
Kumar et al [1] and Kim et al [2] found that pulsed gas metal arc welding (P-GMAW) decreased the spatter and reduced the occurrence of incomplete fusion defects while providing a lower heat input and achieving high penetration. The heat transfer and fluid flow of a molten pool can significantly influence properties such as weld pool geometry, temperature gradients, local cooling rates, and solidification structure. The driving forces for fluid flow in weld pools include the buoyancy force, electromagnetic force, surface tension gradient at the molten pool surface, and the impinging force of the arc plasma [5]. The observation of molten pool behavior presents an effective way to understand how to control the welding process and obtain valuable information for the formation of weld bead shape, which helps in the evaluation of welding quality. The 3D vision sensing system was proposed in order to measure the specular 3D weld pool in gas tungsten arc welding (GTAW), and Zhang et al [12] measured 3D weld pool surface
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