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Electric arc shape and weld bead geometry analysis under the electromagnetic constriction and expansion effect

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Abstract

Arc-based welding processes are susceptible to the magnetic field effects. The electric arc shape, the current density, and the welding energy can influence the weld pool and weld properties, providing an additional degree of freedom for process control. This study analyzed the electromagnetic effect in constriction and expansion on arc shape changing and also the consequence on the weld bead geometry. The results demonstrated that with the electromagnetic field action, the electric arc cross-section was changed from cylindrical to elliptical, and that the greater the coils’ excitation, the greater the effect. It was also observed that with the coil excitation current inversion, the ellipse orientation rotates 90° and that the greater the arc constriction (transversally to weld), the greater the penetration and the shorter the bead width. Furthermore, the greater the electric arc expansion (transversally to weld), the lower the penetration and the greater the bead width. The ellipse is rotated electrically without the need for mechanical movement or reassembly, which makes it easy and agile to rotate the ellipse. The coils are electrically powered which allows a continuous range of excitation current (0 to 10 A) and consequently of forces acting on the change in the electric arc shape. With the coil excitation current increase, there is an electric arc area reduction and, therefore, a current density and heat intensity increase. The use of this device allows an additional independent parameter in arc welding processes and allows different weld bead geometries for the same welding current.

Highlights

  • The electromagnetic constriction and expansion change the cross-section of the electric arc from cylindrical to elliptical, and the inversion of the coil excitation current provides a 90° rotation of this ellipse.

  • The geometric changes of the arc are reflected in the geometry of the bead, that is, the greater the constriction of the arc, the greater the penetration and the smaller the width of the bead. In the same way, the greater the expansion of the electric arc, the smaller the penetration and the greater the width of the bead.

  • The reduction in the area of the electric arc is proportional to the increase in the coil excitation current. This reduction in arc area causes an increase in heat intensity and current density.

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Acknowledgements

Thanks to the Industrial Technical College and to the federal universities of Santa Maria, Minas Gerais, and Santa Catarina for their assistance and partnership.

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Authors and Affiliations

  1. Graduate Program in Mechanical Engineering, Federal University of Minas Gerais, Belo Horizonte, MG, Brazil

    Miguel Guilherme Antonello & Alexandre Queiroz Bracarense

  2. Industrial Technical College CTISM, Federal University of Santa Maria, Av. Roraima no 1000, Santa Maria, RS, Brazil

    Miguel Guilherme Antonello

  3. Mechanical Engineering Department, Federal University of Santa Catarina, Florianópolis, SC, Brazil

    Régis Henrique Gonçalves e Silva, Ivan Olszanski Pigozzo & Marcelo Pompermaier Okuyama

Authors
  1. Miguel Guilherme Antonello
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  2. Alexandre Queiroz Bracarense
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  3. Régis Henrique Gonçalves e Silva
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  4. Ivan Olszanski Pigozzo
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  5. Marcelo Pompermaier Okuyama
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Contributions

Miguel Guilherme Antonello: conceptualization, methodology, validation, formal analysis, investigation, writing—original draft, visualization. Alexandre Queiroz Bracarense: conceptualization, writing—review and editing. Ivan Olszanski Pigozzo: formal analysis, resources. Marcelo Pompermaier Okuyama: formal analysis, resources. Régis Henrique Gonçalves e Silva: resources, writing—review and editing.

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Correspondence to Miguel Guilherme Antonello.

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Antonello, M.G., Bracarense, A.Q., Silva, R.H.G.e. et al. Electric arc shape and weld bead geometry analysis under the electromagnetic constriction and expansion effect. Int J Adv Manuf Technol 118, 1689–1701 (2022). https://doi.org/10.1007/s00170-021-08064-5

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  • DOI: https://doi.org/10.1007/s00170-021-08064-5

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