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The effect of a hot-wire in the tandem GMAW process ascertained by developing a multiphysics simulation model

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Abstract

Physical phenomena such as arc interference, deflection in droplet transfer, and bulging in weld pool are observed in the tandem gas metal arc welding (GMAW) process. A hot-wire with opposite polarities to the leading and trailing electrodes was introduced to counter these phenomena. The effects of the hot-wire were assessed experimentally. A 3D steady-state numerical analysis model was used to calculate the temperatures and the shapes of the leading and trailing arcs, respectively, as well as the arc flows and the electromagnetic forces. The results of our experiments and our numerical analyses clarify the effects of a decrease in the electromagnetic force around tandem electrodes due to the hot-wire. This decrease mitigates arc interference and the deflection in droplet transfer. Furthermore, it plays a role in reducing the height of the bulge generated on the surface of the weld pool. These effects can prevent defects in tandem GMAW processes.

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Acknowledgments

This work was supported by Korea Evaluation Institute of Industrial Technology (KEIT) grant funded by the Korea government (MOTIE) (No. 10062648).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Hanyang University, Seoul, 04763, Korea

    Jin-young Kim, Jaeyoung Lee, Jonghyun Yim & Seung Hwan Lee

  2. Engineering Solution Team, Daewoo Engineering & Construction Co. Ltd., Seoul, 04548, Korea

    Donghyun Van

Authors
  1. Jin-young Kim
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  2. Donghyun Van
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  4. Jonghyun Yim
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  5. Seung Hwan Lee
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Corresponding author

Correspondence to Seung Hwan Lee.

Additional information

Jin-young Kim is currently a Ph.D. candidate of Department of Mechanical Convergence Engineering, Hanyang University, Seoul, Korea. His research interests include welding, additive manufacturing, metallurgy, and multiphysics simulation.

Donghyun Van is a manager of Engineering Solution Team, Daewoo Engineering & Construction Co., Seoul, Korea. His research interests include welding, metallurgy, and multiphysics simulation.

Jaeyoung Lee is a graduate student of Department of Mechanical Convergence Engineering, Hanyang University, Seoul, Korea. His research interests include welding and multiphysics simulation.

Jonghyun Yim is a graduate student of Department of Mechanical Convergence Engineering, Hanyang University, Seoul, Korea. His research interests include welding, and additive manufacturing, metallurgy.

Seung Hwan Lee is a Professor of School of Mechanical Engineering, Hanyang University, Seoul, Korea. He received his Ph.D. in Mechanical Engineering from University of Michigan. His research interests include additive manufacturing, laser process, metallurgy, and artificial Intelligent.

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Kim, Jy., Van, D., Lee, J. et al. The effect of a hot-wire in the tandem GMAW process ascertained by developing a multiphysics simulation model. J Mech Sci Technol 35, 267–273 (2021). https://doi.org/10.1007/s12206-020-1226-9

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  • DOI: https://doi.org/10.1007/s12206-020-1226-9

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