Skip to main content
SpringerLink
Log in

Double arc interference and dynamic behavior characteristics of double wire double-pulsed GMAW

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The double wire gas metal arc welding (GMAW) technology combined with double pulse low-frequency modulation offers the benefits of the higher efficiency of double wire GMAW combined with superior weld joint quality offered by double pulse low-frequency modulation. However, the potential for severe double arc interference of double wire double-pulsed GMAW affects the stability of the welding process and has thus far limited its widespread use. In this study, high-speed photography was used to record the arc profiles and arc interference of double wire double-pulsed GMAW in the synchronous and alternant phases, while the voltage and current waveforms were simultaneously recorded. Experimental results demonstrated that the double arc deflection of the strong pulse was more severe than that of the weak pulse due to the high current associated with a strong pulse. It was also discovered that the trailing arc stiffness was lower than the leading arc stiffness. Moreover, the deflection of trailing arc was greater under the influence of the leading arc’s electromagnetic attraction. Whereas, the arc deflection of the pulse stage in the alternant phase was small, less than that of the pulse stage in the synchronous phase, the arc deflection of the background stage was much greater. Furthermore, the arc deflections of the pulse and background stages in the synchronous phase were smaller than the arc deflection of the background stage in the alternant phase. Finally, the leading and in the synchronous phase maintained their stiffness and demonstrated weaker magnetic arc blow, fewer spatters, a more refined fish-scale appearance, and weld beads with better uniformity.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Häßler M, Rose S, Füssel U (2016) The influence of arc interactions and a central filler wire on shielding gas flow in tandem GMAW. Weld World 60:713–718

    Article  Google Scholar 

  2. Ding XP, Li H, Yang LJ, Gao Y (2013) Numerical simulation of metal transfer process in tandem GMAW. Int J Adv Manuf Technol 69:107–112

    Article  Google Scholar 

  3. Michie K, Blackman S, Ogunbiyi TEB (1999) Twin-wire GMAW: process characteristics and applications. Weld J 78:31–34

    Google Scholar 

  4. Trommer G (2009) Tandem wire process improves ship panel production. Weld J 88:42–45

    Google Scholar 

  5. Lu Y, Chen SJ, Shi Y, Li XR, Chen JS, Kvidahl L, Zhang YM (2014) Double-electrode arc welding process: principle, variants, control and developments. J Manuf Process 16:93–108

    Article  Google Scholar 

  6. Li KH, Chen JS, Zhang YM (2007) Double-electrode GMAW process and control. Weld J 86:231–237

    Google Scholar 

  7. Schwedersky MB, Dutra JC, Silva RHGE, Reisgen U, Willms K (2015) Double-electrode process speeds GTAW. Weld J 94:64–67

    Google Scholar 

  8. Zhang YM, Zhang SB (1998) Double-sided arc welding increases weld joint penetration. Weld J 77:57–62

    Google Scholar 

  9. Zhang YM, Pan C, Male AT (2000) Improved microstructure and properties of 6061 aluminum alloy weldments using a double-sided arc welding process. Metall Mater Trans A 31:2537–2543

    Article  Google Scholar 

  10. Chen JS, Lu Y, Li XR, Zhang YM (2012) Gas tungsten arc welding using an arcing wire. Weld J 91:261–269

    Google Scholar 

  11. Chen DS, Chen MA, Wu CS (2015) Effects of phase difference on the behavior of arc and weld pool in tandem P-GMAW. J Mater Process Technol 225:45–55

    Article  Google Scholar 

  12. Reis RP, Scotti A, Norrish J, Cuiuri D (2012) Investigation on welding arc interruptions in the presence of magnetic fields: welding current influence. IEEE T Plasma Sci 40:870–876

    Article  Google Scholar 

  13. Moinuddin SQ, Sharma A (2015) Arc stability and its impact on weld properties and microstructure in anti-phase synchronized synergic-pulsed twin-wire gas metal arc welding. Mater Des 67:293–302

    Article  Google Scholar 

  14. Ye DJ, Hua XM, Xu C, Li F, Wu YX (2017) Research on arc interference and welding operating point change of twin wire MIG welding. Int J Adv Manuf Technol 89:493–502

    Article  Google Scholar 

  15. Motta MF, Dutra JC, Gohr R, Scotti A (2005) A study on out-of-phase current pulses of the double wire MIG/MAG process with insulated potentials on coating applications. Weld Cut 4:26–32

    Google Scholar 

  16. Palani PK, Murugan N (2006) Selection of parameters of pulsed current gas metal arc welding. J Mater Process Technol 172:1–10

    Article  Google Scholar 

  17. So WJ, Kang MJ, Kim DC (2010) Weld ability of pulse GMAW joints of 780 MPa dual-phase steel. Arch Mater Sci Eng 41:53–60

    Google Scholar 

  18. Yamamoto H, Harada S, Ueyama T, Ogawa S (1993) Study of low-frequency pulsed MIG welding. Weld Int 7:21–26

    Article  Google Scholar 

  19. Sen M, Mukherjee M, Pal TK (2015) Evaluation of correlations between DP-GMAW process parameters and bead geometry. Weld J 94:265–279

    Google Scholar 

  20. Zhang H, Hu SS, Shen JQ, Ma L, Yin FL (2015) Microstructures and mechanical properties of 30Cr-4Mo ferritic stainless steel joints produced by double-pulsed gas metal arc welding. Int J Adv Manuf Technol 80:1975–1983

    Article  Google Scholar 

  21. Silva CLM, Scotti A (2006) The influence of double pulse on porosity formation in aluminum GMAW. J Mater Process Technol 171:366–372

    Article  Google Scholar 

  22. Mathivanan A, Devakumaran K, Kumar AS (2014) Comparative study on mechanical and metallurgical properties of AA6061 aluminum alloy sheet weld by pulsed current and dual pulse gas metal arc welding processes. Mater Manuf Process 29:941–947

    Article  Google Scholar 

  23. Liu AH, Tang XH, Lu FG (2013) Arc profile characteristics of Al alloy in double-pulsed GMAW. Int J Adv Manuf Technol 65:1–7

    Article  Google Scholar 

  24. Li JX, Li H, Wei HL, Ni YB (2016) Effect of pulse on pulse frequency on welding process and welding quality of pulse on pulse MIG welding-brazing of aluminum alloys to stainless steel. Int J Adv Manuf Technol 87:51–63

    Article  Google Scholar 

  25. Reis RP, Souza D, Filho DF (2015) Arc interruptions in tandem pulsed gas metal arc welding. J Manuf Sci E T ASME 137:602–611

    Google Scholar 

  26. Xiang T, Li H, Wei HL, Gao Y (2016) Arc characteristics and metal transfer behavior of twin-arc integrated cold wire hybrid welding. Int J Adv Manuf Technol 87:2653–2663

    Article  Google Scholar 

  27. Ueyama T, Ohnawa T, Tanaka M, Nakata K (2007) Occurrence of arc interaction in tandem pulsed gas metal arc welding. Sci Technol Weld Join 12:523–529

    Article  Google Scholar 

  28. Yudodibroto BYB, Hermans MJM, Richardson IM (2006) The influence of pulse synchronisation on the process stability during tandem wire arc welding. IIW Doc.XII-1910-06 12:77–85

  29. Andersson J, Tolf E, Hedegard J (2006) The fundamental stability mechanism in tandem MIG/MAG welding, and how to perform implementation. IIW Doc.XII-1895-06 12:65–75

  30. Scotti A, Morais CO, Vilarinho LO (2006) The effect of out-of-phase pulsing on metal transfer in twin-wire GMA welding at high current level. Weld J 85:225–230

    Google Scholar 

  31. Ghosh PK, Dorn L, Kulkarni S, Hofmann F (2009) Arc characteristics and behaviour of metal transfer in pulsed current GMA welding of stainless steel. J Mater Process Technol 209:1262–1274

    Article  Google Scholar 

  32. Ghosh PK, Dorn L, Hübner M, Goyal VK (2007) Arc characteristics and behavior of metal transfer in pulsed current GMA welding of aluminum alloy. J Mater Process Technol 194:163–175

    Article  Google Scholar 

Download references

Funding

This work was supported by the National Natural Science Foundation of China (grant no. 51205136), the Competitive Allocation Project Special Fund of Guangdong Province Chinese Academy of Sciences Comprehensive Strategic Cooperation (grant no. 2013B091500082), the Fundamental Research Funds for the Central Universities (Key Program) (grant no. 2015ZZ084), the Science and Technology Planning Project of Guangzhou (grant no. 201604016015), and the China Scholarship Council (grant no. 201606155058).

Author information

Authors and Affiliations

  1. School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou, 510640, China

    Kaiyuan Wu, Jiajia Wang, Tong Yin, Zuwei He & Zhuoyong Liang

  2. Engineering Research Center for Special Welding Technology and Equipment of Guangdong Province, South China University of Technology, Guangzhou, China

    Kaiyuan Wu, Jiajia Wang, Tong Yin, Zuwei He & Zhuoyong Liang

Authors
  1. Kaiyuan Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jiajia Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Tong Yin
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Zuwei He
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zhuoyong Liang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Kaiyuan Wu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wu, K., Wang, J., Yin, T. et al. Double arc interference and dynamic behavior characteristics of double wire double-pulsed GMAW. Int J Adv Manuf Technol 95, 991–1002 (2018). https://doi.org/10.1007/s00170-017-1269-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-1269-y

Keywords

Search

Navigation