Arc Hybrid Welding Research Articles

A novel method for fully penetrated U-rib-to-deck joints: Single-sided oscillating laser arc hybrid welding

U-rib-to-deck (RTD) joints represent one of the most critical and vulnerable welding details of orthotropic steel decks. Aiming for full penetration and high-level service performance, a novel method with single-sided oscillating laser-arc hybrid welding (OLAHW) technique was proposed for the RTD joint. The weld formation, microstructure and mechanical properties were extensively investigated. The results indicated that the porosity and lack of fusion (LoF) defects effectively suppressed with the beam oscillation during LAHW process. The OLAHW technique has good spatial accessibility with larger laser beam incidence angle of 20° Beam oscillation led to an increase in acicular ferrite in the fusion zone (FZ) while simultaneously a reduction of martensite in the heat effected zone (HAZ). This was related to the cooling time, and the thermal simulation results revealed that the OLAHW sample demonstrated comparable cooling times in both the Laser-FZ and arc-FZ. Consequently, beam oscillation can generated more homogeneous microstructures and microhardness. Although the microhardness of the OLAHW sample in the FZ was increased compared to the conventional arc welding (CAW) and LAHW sample, the highest microhardness value remained within acceptable limits (380 HV). Moreover, the ultimate tensile strength of the OLAHW weld sample increased by 7 % compared to the CAW weld sample. The application of the OLAHW technique demonstrates its feasibility for engineering applications in orthotropic steel decks manufacturing.

Investigating the Influence Mechanism of Different Shielding Gas Types on Arc Characteristics and Weld Quality in TA2 Laser–Arc Hybrid Welding

The effective welding of a 6 mm thick TA2 pure titanium medium-thickness plate was achieved by laser–arc hybrid welding (LAHW) with helium–argon mixed shielding gas. Conducted research on the influence of helium–argon mixed shielding gas on plasma and arc characteristics during welding, and its further impact on the microstructure, internal porosity defects, tensile properties, and corrosion resistance of welded joints was explored. The study demonstrated that under the shielding gas with 75% helium, the arc width narrowed significantly from 6.96 mm to 2.61 mm, achieving a 63% reduction, which enhanced the concentration of arc heat flux density. Achieved a well-formed weld with no surface spatter and significantly reduced the internal porosity rate from 3.02% to 0.47%, which is an 84% decrease. Tensile fractures are located in the base material, all exhibiting plastic failure. The corrosion resistance of the welded joint initially increased and then decreased with the increase of helium content in the shielding gas, peaking at 75% helium content.

Effect of oxygen in shielding gas on weldability in plasma-GMA hybrid welding process of high-tensile strength steel

This study aims to clarify the effect of oxygen in shielding gas on weldability in the plasma-GMA (Gas Metal Arc) hybrid welding process of high-tensile strength steel plates. The difference in keyhole profile and bead formation, when the GMA shielding gas was pure Ar, Ar + 2% O2, or Ar + 20% CO2, was investigated for plate thicknesses of 6 and 9 mm for the first time. It was found that the weld beads were in good condition for 6 mm thickness plates for all shielding gases, which implied that the window of welding conditions for this thickness is wide. In contrast, for 9 mm thickness plates, a fully penetrated weld bead was achieved only in Ar + 20% CO2, and weld bead penetration in Ar + 20% CO2 is higher than in pure Ar and Ar + 2% O2 in the same welding condition. Due to decreased surface tension caused by sufficiently increased oxygen absorbed into the weld pool, the keyhole diameter increased to penetrate the bottom side of the plate, and the depressing weld pool surface under GMA allowed the heat input from the GMA to be directly applied to a deeper position. Consequently, the plasma-GMA hybrid welding process with Ar + 20% CO2 achieved a complete penetration for a plate of 9 mm thickness, owing to the effects of both phenomena. It proved a potential to increase penetrability in welding thicker plates by controlling oxygen content in shielding gas of GMA adequately.

Research on the Welding Process and Weld Formation in Multiple Solid-Flux Cored Wires Arc Hybrid Welding Process for Q960E Ultrahigh-Strength Steel.

This paper proposes a novel welding process for ultrahigh-strength steel. The effects of welding parameters on the welding process and weld formation were studied to obtain the optimal parameter window. It was found that the metal transfer modes of solid wires were primarily determined by electrical parameters, while flux-cored wires consistently exhibited multiple droplets per pulse. The one droplet per pulse possessed better welding stability and weld formation, whereas the short-circuiting transfer or one droplet multiple pulses easily caused abnormal arc ignition that decreased welding stability, which could easily lead to a "sawtooth-shaped" weld formation or weld offset towards one side with more spatters. Thus, the electrical parameters corresponding to one droplet per pulse were identified as the optimal parameter window. Furthermore, the weld zone (WZ) was predominantly composed of AF, and the heat-affected zone (HAZ) primarily consisted of TM and LM. Consequently, the welded joint still exhibited excellent mechanical properties, particularly toughness, despite higher welding heat input. The average tensile strength reached 928 MPa, and the impact absorbed energy at -40 °C for the WZ and HAZ were 54 J and 126 J, respectively. In addition, the application of triple-wire welding for ultrahigh-strength steel (UHSS) demonstrated a significant enhancement in post-weld deposition rate, with increases of 106% and 38% compared to single-wire and twin-wire welding techniques, respectively. This process not only utilized flux-cored wire to enhance the mechanical properties of joints but also achieved high deposition rate welding.

Effect of distance between heat sources on droplet transfer behavior and weld formation of AH36 during laser and CWW GMAW arc hybrid welding

Effect of distance between heat sources on droplet transfer behavior and weld formation of AH36 during laser and CWW GMAW arc hybrid welding

RESEARCH STATUS AND PROSPECTS FOR TIG-MIG HYBRID-ARC-WELDING TECHNOLOGY

TIG-MIG hybrid welding integrates the merits of tungsten insert-gas welding (TIG) and metal inert-gas welding (MIG), and achieves a new material-joining process with high quality, high efficiency and low cost. However, TIG-MIG hybrid welding also had some shortcomings, such as a complex process, unstable arc, large heat input, limiting its application. To further improve and promote TIG-MIG hybrid welding, numerous universities and research institutes have put forward a series of improvement programs that achieve relatively good results. In this study TIG-MIG hybrid welding is discussed in three aspects: the welding-process improvement, welding-parameters optimization and numerical simulation of the welding process. It was found that the stability of the hybrid arc welding process and the quality of the weld bead can be improved by improving the current polarity, wire type and arc swing. The TIG current, the distance between the wire and tungsten, and the heat input had an important impact on the weld quality and the formation of defects. A numerical simulation of the welding process analyzed the effects of torch angle, the distance between the wire and tungsten, the welding speed and the temperature fields on the arc morphology, molten-pool behavior, and droplet transfer. According to the above analysis, it summarized the current research status of TIG-MIG hybrid welding, and then proposed future research directions based on the existing shortcomings and deficiencies.

Effect of Solid-State Phase Transformation and Transverse Restraint on Residual Stress Distribution in Laser-Arc Hybrid Welding Joint of Q345 Steel.

A Q345 steel butt-welded joint was manufactured using laser-arc hybrid welding (LAHW) technology, and its microstructure, microhardness, and residual stress (RS) distribution were measured. Using ABAQUS software, a sequentially coupled thermo-metallurgical-mechanical finite element method was employed to model the welding RS distribution in the LAHW joint made of Q345 steel. The effects of solid-state phase transformation (SSPT) and transverse restraint on the welding RS distribution were explored. The results show that a large number of martensite phase transformations occurred in the fusion zone and heat-affected zone of the LAHW joint. Furthermore, the SSPT had a significant effect on the magnitude and distribution of RS in the LAHW joint made of Q345 steel, which must be taken into account in numerical simulations. Transverse restraints markedly increased the transverse RS on the upper surface, with a comparatively minor impact on the longitudinal RS distribution. After the transverse restraint was released, both the longitudinal and transverse RS distributions in the LAHW joint reverted to a level akin to that of the welded joint under free conditions.

Development of an in situ alloying method for high-performance welding processes to achieve an LTT effect by local modification of the alloy content

One possible option for increasing the fatigue strength of welded joints is the use of so-called low transformation temperature (LTT) alloys. The aim is to introduce residual compressive stresses into the weld to counteract crack initiation and propagation. Until now, there has been no application of an LTT effect to high-performance welding processes such as the laser beam submerged arc hybrid welding process (LUPuS hybrid). First, the LUPuS hybrid single-wire process was further developed into the LUPuS tandem hybrid process. This makes it possible to equip the two submerged arc welding torches with different commercially available filler wires. The aim of the work is to further develop the LUPuS tandem hybrid welding process to enable the use of the LTT effect. The in situ alloying process for obtaining the LTT effect from commercially available material combinations was extended to the two-wire process. The alloy obtained was investigated by means of energy dispersive x-ray spectroscopy and hardness measurements and the influence on residual stresses was determined by the borehole method supported by electronic speckle pattern interferometry.

Study on the Physical Characteristics of Plasma and Its Relationship with Pore Formation during Laser-Metal Active Gas Arc Hybrid Welding of 42CrMo Steel

The automobile industry puts forward higher requirements for the design and manufacture of steel pistons. However, the welding of 42CrMo steel pistons still has unsolved technical problems, especially welding defects that cannot be directly detected, such as pores, which are easily generated inside the weld. A plasma experiment of laser-metal active gas arc (MAG) hybrid welding 42CrMo steel was conducted in this paper, and plasma signals inside and outside the keyhole were detected during the laser welding, leading laser laser-MAG hybrid welding, and leading arc laser-MAG hybrid welding of 42CrMo steel. The characteristic parameters such as electron temperature and electron density were calculated and analyzed to investigate the relationship between plasma behavior and the formation of weld porosity in the welding process of 42CrMo steel. Based on the fluctuations in plasma electron temperature and electron density, the prediction of pore formation in the weld of 42CrMo steel was made, aiming to provide guidance for achieving a stable and reliable laser-MAG hybrid welding process for 42CrMo steel.

Numerical and experimental investigation of metal droplet transfer during pulsed bypass-current plasma-GMAW hybrid arc welding

Numerical and experimental investigation of metal droplet transfer during pulsed bypass-current plasma-GMAW hybrid arc welding

Numerical analysis of the behavior of molten pool and the suppression mechanism of undercut defect in TIG-MIG hybrid welding

In order to investigate the multi-coupling transport phenomena in TIG-MIG hybrid arc welding, a three-dimensional model including droplet and molten pool was established. An innovative distribution pattern of arc heat and force that adapted to the evolution of molten pool surface was proposed, achieving a unified distribution of "arc current density-arc pressure-electromagnetic force-arc heat". The effect of TIG arc on molten pool behavior and undercut defect was quantitatively analyzed by comparing TIG-MIG hybrid welding with traditional MIG welding. The results showed that the electromagnetic repulsion between the two arcs with opposite currents increased the aspect ratio of the hybrid arc heat and force distribution. It led to a long and narrow gouging region, where the promoting effect of inertial force on the undercut was weakened by arc pressure and hydrostatic pressure. The liquid metal with a lower cooling rate had sufficient time to fully fill the weld toe and suppressed undercut. Sensitivity and dimensional analysis illustrated that the TIG-MIG hybrid arc eliminated undercut by reducing the inertia force, adjusting the arc pressure distribution, and enhancing the hydrostatic pressure. The groove sizes was predicated based on molten pool characteristics, including the stress state of liquid metal, morphology, and fluid flow patterns. It revealed the quantitative relationships among welding parameters, behavior of molten pool, and weld bead formation, promoting the implementation of digital twinning technology in the manufacturing industries.

Unveiling arc deflection instability in narrow gap laser-arc hybrid welding of thick Ti-6Al-4V plate

Unveiling the mechanism behind arc deflection under narrow gap laser arc hybrid welding (NGLAHW) is of paramount significance in mitigating laser-arc coupling failure and welding porosity for thick Ti-6Al-4V plate structure. This paper utilizes high-speed camera technology, data statistics and model prediction to comprehensively study the influence of constrained groove space and droplet transfer mode on arc deflection. The results demonstrate that narrowing groove gap exerts a substantial compressive effect on welding arc behavior, particularly rendering it more susceptible to arc deflection when the groove gap is smaller than the arc length. The small droplet transfer mode is characterized by stable arc behavior, whereas the large droplet transfer mode tends to be susceptible to arc instability due to the droplet deviation induced by turbulent metal vapor. Particularly noteworthy is the emergence of substantial arc deflection when the droplet deviation exceeds the critical threshold of 0.51 mm, which diminishes the driving force for droplet transfer and subsequently leading to potential short-circuiting explosions and unstable welding process. Moreover, the lateral force induced by arc deflection drives a deviation in arc heat source with accelerated solidification of molten pool, consequently resulting in an elevation in welding porosity. This paper has provided a comprehensive insight into the mechanism driving arc deflection in NGLAHW, which holds paramount importance in enabling effective strategies to regulate the arc behavior.

Numerical simulation of coupling behavior in coaxial hybrid arc welding apparatus

Double-layer coaxial hybrid arcing technology has been developed based on an inner constraint arc and an outer ring arc; the heat and pressure properties of the arc source are supposed to be decoupled and leading to improved controllability of the weld pool thermal-force state. But, the coupling state between the two arcs is not uncovered, and the process window for stable hybrid arc is narrow. In this study, a numerical model of the coaxial hybrid arc system is established, the influence of the water-cooled nozzle on the arc is considered, and the model's accuracy is verified by the measured arc pressure. The physical fields, such as temperature, velocity, and current density distribution, of the hybrid arc are calculated, and the influence of the inner constraint arc current or outer ring arc current on arc pressure and the coupling state in the hybrid arc are uncovered. It was found that (1) at the center of the stable hybrid arc, the current density, magnetic flux intensity, Lorentz force, and arc pressure with a rise in constraint arc current are higher than with a rise in outer arc current; (2) given the total current, adjust the proportion of the inner or outer arc currents, the total heat input basically remains unchanged; and (3) the cause of the arc collapse phenomenon, which is challenging to explain experimentally: the non-ionized gas layer in the orifice throat is broken through.

KTIG–MIG hybrid arc welding process

Metal-inert gas welding is an important welding process but the process instability easily induces spatter and undercut defects. To improve the welding process stability, a new hybrid arc welding process, named KTIG–MIG, was proposed in this paper. Arc characteristics were preliminarily studied. It is found that in KTIG–MIG hybrid welding, MIG arc is stable even it is shielded with pure argon gas; stable spray transfer is easily achieved in a much wider process window, especially the lowest voltage to achieve spray transfer is greatly reduced; KTIG arc voltage decreases than that in single KTIG arc, and MIG arc current is higher than the pre-set value. Cooling state of the KTIG tungsten plays a key role in slowing tungsten erosion.

A Review of Numerical Simulation of Laser-Arc Hybrid Welding.

Laser-arc hybrid welding (LAHW) is known to achieve more stable processes, better mechanical properties, and greater adaptability through the synergy of a laser and an arc. Numerical simulations play a crucial role in deepening our understanding of this interaction mechanism. In this paper, we review the current work on numerical simulations of LAHW, including heat source selection laws, temperature field, flow field, and stress field results. We also discuss the influence of laser-arc interaction on weld defects and mechanical properties and provide suggestions for the development of numerical simulations of LAHW.

Experimental comparison on load-carrying capacity of corner joints by laser-arc hybrid welding and arc welding

Experimental comparison on load-carrying capacity of corner joints by laser-arc hybrid welding and arc welding

Microstructure and mechanical properties of aluminum-steel dissimilar metal welded using arc and friction stir hybrid welding

In this study, arc and friction stir hybrid welding (AFSHW) was proposed to weld aluminum-steel dissimilar metals in attempt to realize high quality joining. Firstly, an interlayer was produced on galvanized steel by using bypass current-metal inert gas welding (BC-MIG), and then an aluminium plate was jointed via Friction stir lap welding (FSLW). The effects of tool pin length and FSLW times on the microstructure and mechanical properties of dissimilar joints were fully investigated by means of Optical Microscopy (OM), Scanning Electron Microscope (SEM), Electron Backscatter Diffraction (EBSD), and mechanical testing. The results show that as pin length increased, joint strength tended to increase and then decrease, and the tensile failure partially occurred at aluminium base metal. However, with additional number of FSLW, joint strength would be reduced, which was attributed to attenuated dislocation density and strain concertation in dissimilar joint. The research outcomes will provide a new welding method to obtain sound Al-Fe dissimilar metal joint, and benefit to a better understanding of Al-Fe joining mechanism.

Effects of bypass-current and out plasma current on droplet transfer behaviours during plasma-MIG hybrid arc welding

A new method, bypass-current plasma-MIG hybrid arc welding, was proposed to weld AA 5083 aluminium alloy. A comparative investigation between simulation and experiment was performed to quantify different effects of bypass-current and out plasma current on droplet transfer behaviours. The results show that when the bypass-current is 15 A, the droplets present a projected transfer mode, and its period is 22 ms. But if the outer plasma current is 15 A, the transfer frequency increases 19.1 Hz, and the sizes of the droplet show a slight increase. This is due to the reduction of electromagnetic force and arc plasma force on droplets. The research outcomes provide benefits to the droplet transfer behaviours in control and optimisation during aluminium alloy welding.

Microstructure and Texture Characterization of Duplex Stainless Steel Joints Welded by Alternating Magnetic Field-Assisted Hybrid Laser-GMAW Welding.

In this study, 2205 duplex stainless steel with 12 mm thickness was welded by alternating magnetic field-assisted laser arc hybrid welding. The effect of an alternating magnetic field on the proportion distribution of two phases of the welded joint was investigated. The texture distribution, grain boundary misorientation, and grain size of welded joints were analyzed and characterized. The uniform distribution of alloying elements in the two phases was improved by a 20 mT alternating magnetic field. The diffusion dissolution of Ni and N elements into the γ phase was promoted, which was conducive to the transition from the α to γ phase and reduced the precipitation of Cr2N, such that the ratio of γ to α was 43.4:56.6. The ratio of the two phases of the weld was balanced by the alternating magnetic field of 30 mT, such that the ratio of γ and α was 44.6:55.4 and the texture dispersion was weakened. The Σ3 twinning boundary of the austenite phase in the weld was transformed to HABs, the ferrite phase underwent dynamic recrystallization, and the austenite phase had a cube texture, copper texture, and goss texture.

Direction-independent laser-GMA hybrid welding with coaxial wire feed and annular beam

Conventional laser gas metal arc hybrid welding (LB-GMA hybrid welding) is used as an efficient joining process in several high-tech steel processing production facilities. However, the use of the LB-GMA hybrid welding is often limited to the joining of linear weld seams as the welding process has a preferred welding direction due to lateral positioning of the laser beam and welding wire electrode. Reorienting the welding direction, therefore, often results in weld defects since changing the welding direction also requires a geometric manipulation of the GMA torch in relation to the laser beam optics. This means a considerable additional effort that is necessary if this efficient welding process is to be used for geometrically complex weld seam contours. Furthermore, the conventional LB-GMA hybrid welding process has a high adjustment complexity. Within this work, a direction-independent laser GMA hybrid welding head with an annular beam and coaxial wire feed is used. The annular laser beam with homogenous intensity profile is formed by a special processing head, split and reassembled around the coaxial wire. Due to the coaxial arrangement of the wire electrode to the annular beam, the hybrid process is in theory direction independent. As a result, there should not be any irregularities in the weld seam, when the welding direction is changed. The annular beam considerably reduces the complexity of adjustment and improves reproducibility. The focus of this work is to qualify the process for joining geometrically complex weld contours and to investigate possible advantages of the directional independence of the coaxial LB-GMA hybrid welding process. For this purpose, fillet welds in lap joint configuration with a sheet thickness of 2 mm each at different weld contours (different direction changes, corners, radii) are discussed. By performing a DoE-based sensitivity analysis, influencing factors on the quality of the generated weld are analysed.