The study on the drop detachment for automatic pipeline GMAW system: short-circuit mode

  • Alireza Doodman TipiEmail author


In the automatic pipeline welding systems, the welding properties are varied regarding to the robot angle variations around the pipe. In this paper, a modified dynamic model—presented for the free-flight mode [1]—is extended to include the short-circuit mode. Consequently, a complete dynamic model is introduced including some modifications in characteristics equations. Some events and phenomena, like frequency jumping and combined transfer mode—caused by angle variations—are illustrated using time-frequency representation through the simulation and experimental examples.


Gas metal arc welding Short-circuit mode Drop detachment Characteristic equations Dynamical behavior Time-frequency analysis 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


  1. 1.
    Doodman Tipi AR, Haeri M (2010) Studying of detachment for automatic pipeline GMAW system—part I: free flight transfer. I J Adv Manu Technol (in press)Google Scholar
  2. 2.
    Benyounis KY, Olabi AG (2008) Optimization of different welding processes using statistical and numerical approaches: a reference guide. Adv Eng Softw 39:483–496CrossRefGoogle Scholar
  3. 3.
    Kim IS, Son JS, Kim IG, Kim JY, Kim OS (2003) A study on relationship between process variable and bead penetration for robotic CO2 arc welding. J Mater Process Technol 136:139–145CrossRefGoogle Scholar
  4. 4.
    Raveendra J, Parmar RS (1987) Mathematical models to predict weld bead geometry for flux cored arc welding. Met Constr 19:31–35Google Scholar
  5. 5.
    Manonmani K, Murugan N, Buvanasekaran G (2005) Effect of process parameters on the weld bead geometry of laser beam butt welded stainless steel sheets. Int J Adv Manuf Technol 17:103–109Google Scholar
  6. 6.
    Kannan T, Murugan N (2006) Effect of flux cored arc welding process parameters on duplex stainless steel clad quality. J Mater Process Technol 176:230–239CrossRefGoogle Scholar
  7. 7.
    Ridings GE, Thomson RC, Thewlis G (2002) Prediction of multi wire submerged arc weld bead shape using neural network modeling. Sci Technol Weld Join 7:265–279CrossRefGoogle Scholar
  8. 8.
    Lee HK, Han HS, Son KJ, Hong SB (2006) Optimization of Nd-YAG laser welding parameters for sealing small titanium tube ends. Mater Sci Eng A 415:149–155CrossRefGoogle Scholar
  9. 9.
    Canyurt OE (2005) Estimation of welded joint strength using genetic algorithm approach. Int J Mech Sci 47:1249–1261zbMATHCrossRefGoogle Scholar
  10. 10.
    Thomsen JS (2004) Advanced control methods for optimization of arc welding. Ph.D. thesis, Dep Cont Eng, Aalborg University, DenmarkGoogle Scholar
  11. 11.
    Ushio M, Mao W (1996) Modeling of the arc sensor for DC MIG/MAG welding in open arc mode—a study on the improvement of the sensitivity and the reliability of the arc sensor in GMA welding (1st report). J Jpn Weld Soc 14:99–107Google Scholar
  12. 12.
    Kim JW, Na SJ (1991) A study on prediction of welding current in GMAW. Proc Inst Mech Eng Part B 205:59–63CrossRefGoogle Scholar
  13. 13.
    Richardson IM, Bucknall PW, Stares I (1994) The influence of power source dynamics on wire melting rate in pulsed GMAW. Weld J 73:32–37Google Scholar
  14. 14.
    Choi SK, Yoo CD, Kim YS (1998) Dynamic simulation of metal transfer in GMAW—part 1: globular and spray transfer modes. Weld J 77:38–44Google Scholar
  15. 15.
    Choi JH, Lee JY, Yoo CD (2001) Simulation of dynamic behavior in a GMAW system. Weld J 80:239–246Google Scholar
  16. 16.
    Quinn TP, Madigan RB, Siewert TA (1994) An electrode extension model for gas metal arc welding. Weld J 73:241–248Google Scholar
  17. 17.
    Ishichenko YS (1993) Relationships governing droplet transfer during a short circuit. Weld Int 7:627–631CrossRefGoogle Scholar
  18. 18.
    Choi SK, Ko SH, Yoo CD, Kim YS (1998) Dynamic simulation of metal transfer in GMAW—part 2: short circuiting transfer mode. Weld J 77:45–52Google Scholar
  19. 19.
    Hermans MJM, Den Ouden G (1999) Process behavior and stability in short circuit gas metal arc welding. Weld J 78:137–141Google Scholar
  20. 20.
    Hermans, MJM (1997) A study of short circuiting arc welding. PhD thesis, Delf Univ, NetherlandsGoogle Scholar
  21. 21.
    Chu YX, Hu SJ, Hou WK, Wang PC, Marin SP (2004) Signature analysis for quality monitoring in short circuit. Weld J 83:336–343Google Scholar
  22. 22.
    Bless SJ (1974) Drop transfer in short-circuit welding. J Phys D Appl Phys 7:526–539CrossRefGoogle Scholar
  23. 23.
    Wu CS, Chen MA, Li SK (2004) Analysis of excited droplet oscillation and detachment in active control of metal transfer. Comp Mater Sci 31:147–154CrossRefGoogle Scholar
  24. 24.
    Planckaert JP, Djermoune EH, Brie D, Briand F, Richard FP (2006) Droplet features extra condition with a dynamic active contour for MIG/MAG welding modeling. In: 18th Int Conf Sys Eng (ICSE 2006), Coventry Univ, UKGoogle Scholar
  25. 25.
    Simpson SW, Zhu P (1995) Formation of molten droplets at a consumable anode in an electric welding arc. J Phys D Appl Phys 28:1594–1600CrossRefGoogle Scholar
  26. 26.
    Jones LA, Eagar TW, Lang JH (1998) Magnetic forces acting on molten drops in gas metal arc welding. J Phys D Appl Phys 31:93–106CrossRefGoogle Scholar
  27. 27.
    Haidar J, Lowke JJ (1996) Predictions of metal droplet formation in arc welding. J Phys D Appl Phys 29:2951–2960CrossRefGoogle Scholar
  28. 28.
    Nemchinsky VA (1994) Size and shape of the liquid droplet at the molten tip of an arc electrode. J Phys D Appl Phys 27:1433–1442CrossRefGoogle Scholar
  29. 29.
    Lancaster JF (1986) The physics of welding, 2nd edn. Pergamon, New YorkGoogle Scholar
  30. 30.
    Johnson JA, Smartt HB, Harmer T, Moore KL, Reutzel EW, Einerson CJ (1995) Derivation and calibration of a gas metal arc welding (GMAW) dynamic droplet model. In: Trends in Welding Research, Proc 4th Int Conf, pp 377–384Google Scholar
  31. 31.
    Modenesi PJ, Reis RI (2007) A model for melting rate phenomena in GMA welding. J Mater Process Technol 189:199–205CrossRefGoogle Scholar
  32. 32.
    Palani PK, Murugan N (2006) Modeling and simulation of wire feed rate for steady current and pulsed current gas metal arc welding using 317L flux cored wire. Int J Adv Manuf Technol 34:1111–1119CrossRefGoogle Scholar
  33. 33.
    Jones LA, Eagar TW, Lang JH (1998) A dynamic model of drops detaching from a gas metal arc welding electrode. J Phys D Appl Phys 31:107–123CrossRefGoogle Scholar
  34. 34.
    Doodman Tipi AR, Mortazavi SA (2008) A new adaptive method (AF-PID) presentation with implementation in the automatic welding robot. IEEE/ASME Int Conf Mechat Embed Sys Appl (MESA08), Beijing, ChinaGoogle Scholar

Copyright information

© Springer-Verlag London Limited 2010

Authors and Affiliations

  1. 1.Kermanshah University of TechnologyKermanshahIran

Personalised recommendations