Double-wire double-pulsed gas metal arc welding (DP-GMAW) experiments were conducted in the double pulse synchronous (DPS), alternating (DPA), and independent (DPI) phases. The effects of current phase on weld seam formation were analyzed. Experimental results showed that a stable welding process was achieved in all three current phases and the derived weld seams demonstrated little spatter, no hump, or undercut. Different current phases had little influence on weld reinforcement and width, but had a significant influence on weld penetration and toe angle. The fish-scale ripples of weld seams were prominent; specifically, the fish-scale ripples in the DPA phase were more prominent than those in other current phases. The penetration and penetration shape factor (PSF) in the DPA phase were at their highest while those in the DPS phase were at their lowest. In the DPS phase, the ferrite was coarse and in higher quantity, while the pearlite was relatively in lower quantity. In the DPA phase, the ferrite was finer and in lower quantity, while the pearlite was relatively in higher quantity and the microstructure was more uniform. Last, in the DPI phase, the microstructure appeared in a state between the DPS and DPA phases.
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