Abstract
Plasma arc welding (PAW)-cable-type seven-wire GMAW (gas metal arc welding) hybrid welding is known as a high-efficiency welding combining plasma arc, GMAW arc and cable-type welding wire. In this study, numerical simulation via Fluent of the molten pool temperature field and flow field and experimental verification were conducted on Q235 thin plate hybrid welding with cable-type wire to explore molten pool fluid behavior. The simulation results show that keyholes form in the molten pool due to the strong penetration ability of a plasma arc and then the evolved pores by the surface tension float out of the molten pool. When the GMAW welding current increases, both the length and width of the weld pool enlarge, the weld reinforcement increases and the flow rate of molten metal in the weld pool also speeds up. While the PAW current increases, the weld pool length also increases and the molten metal in the weld pool significantly flows faster, but the weld reinforcement decreases. When the welding speed increases, the weld pool length and fusion depth decrease, but the reinforcement will first increase and then decrease. The experimental results are in strong agreement with the simulation results. It shows that the numerical analysis model established in this paper is accurate, laying a certain theoretical foundation for the popularization of PAW-cable-type seven-wire GMAW hybrid welding.
Highlights
Arc welding has a large place in today’s industrial production
The results show that the temperature field distribution range of double cable gas metal arc welding (GMAW) welding pool is wider, which can effectively reduce the pool temperature and is suitable for narrow gap welding
Plasma arc mainly contributes to larger fusion depth, while GMAW arc is mainly for larger fusion width
Summary
Arc welding has a large place in today’s industrial production. Hybrid welding by superimposing multiple arc welding heat sources can greatly improve welding efficiency [1,2].In the 1970s, W. Arc welding has a large place in today’s industrial production. Hybrid welding by superimposing multiple arc welding heat sources can greatly improve welding efficiency [1,2]. C. Liefken from Philips Research Labs (the Netherlands) proposed a new process combining plasma arc welding (PAW) and metal inert-gas welding (MIG) [3], which can achieve greater depth of fusion by the compressed plasma arc and larger width of fusion by the spreading MIG arc so as to improve welding quality and welding efficiency. With the development of welding technology, two types of plasma-MIG hybrid welding have been evolved—a coaxial type by Philips and a paraxial by the Paton Welding Institute [4,5,6]. The research findings about gas metal arc welding (GMAW)
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