Skip to main content
SpringerLink
Log in

Analysis of conductive channel and heat transfer mechanism of triple-wire gas indirect arc welding

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

Abstract

Triple-wire gas indirect arc welding (TW-GIA) is a new high-efficiency technology with low heat input and high deposition rate. However, the research on the arc conductive channel and energy transfer characteristics of TW-GIA is not deep enough, which makes it impossible to accurately adjust the heat transfer and restricts the further application of this technology. In this paper, the spectrometer was used to collect arc spectral information, the Boltzmann diagram method was adopted to estimate electron temperature and electron density, and physical models were constructed to discuss the heat transfer mechanism. The results show that the conductive channel of TW-GIA is established between the main wire and the side wires. Due to the coupled magnetic field generated by the two current branches, the Lorentz force on the TW-GIA arc plasma is directed towards the extension of the main wire, resulting in the arc to be compressed in the X-axis and elongated in the Z-axis as the welding current increases. The electron temperature gradient an “inverted cone” characteristic, which can be divided into high-temperature area (HTA), low-temperature area (LTA), and peripheral area (PA). The ranges of HTA and LTA both expand with the increase of welding current, and the size ratio of HTA to LTA is gradually increased. Due to the reduction of electron density and contact area, the heat-affected zone width with three areas is smaller than that of GMAW, and the average temperature around the weld is reduced by 24.3%, 31.8%, and 45.9%, respectively, when adopting HTA, LTA, and PA.

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

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

Data availability

All the data have been presented in the manuscript.

References

  1. Gao Y, Zhang Y, Li J, Liu K, Xu Y, Zhou JP (2021) Research on the performance of laser-MIG arc tandem welding of CP-Ti/304 stainless steel bimetallic sheets. Mater Lett 305(15):130805. https://doi.org/10.1016/j.matlet.2021.130805

    Article  Google Scholar 

  2. Kim JY, Van D, Lee J, Yim J, Lee SH (2021) The effect of a hot-wire in the tandem GMAW process ascertained by developing a multiphysics simulation model. J Mech Sci Technol 35(1):267–273. https://doi.org/10.1007/s12206-020-1226-9

    Article  Google Scholar 

  3. Lahnsteiner R (1992) TIME process - an innovative MAG welding process. Weld Rev Int 11(1):17–20

    Google Scholar 

  4. Zhang Y (2007) Metal transfer in double-electrode gas metal arc welding. J Manuf Sci Eng 129(6):991–999. https://doi.org/10.1115/1.2769729

    Article  Google Scholar 

  5. Purwaningrum Y, Kusriyanto M, Kurniawan R, Rizky O (2018) Effect of DE-GMAW (Double electrode gas metal arc welding)’s resistance on mechanical and physical properties of aluminium alloy weld. Key Eng Mater 789:64–68. https://doi.org/10.4028/www.scientific.net/KEM.789.64

    Article  Google Scholar 

  6. Wu DT, Zou Y, Zhao GL, Shi C (2020) Wear-resistant surfacing layer preparated by high efficiency twin-wire indirect arc welding. Mater Sci Forum 985:229–239. https://doi.org/10.4028/www.scientific.net/MSF.985.229

    Article  Google Scholar 

  7. An Q, Wen Y, Matsuda K, Xu J, Zou Y (2021) Corrosion resistance and high temperature wear behavior of carbide-enhanced austenite-based surfacing layer prepared by twin-wire indirect arc welding. Mater Res Express 8(1):016529. https://doi.org/10.1088/2053-1591/abda65

    Article  Google Scholar 

  8. Wu DT, Hu C, Zhao W, Zhang YG, Zou Y (2019) Influence of external magnetic field on twin-wire indirect arc surfacing stainless steel layer. Vacuum 169:1–7. https://doi.org/10.1016/j.vacuum.2019.108958

    Article  Google Scholar 

  9. Fang DS, Song G, Liu LM (2016) A novel method of triple-wire gas indirect arc welding. Mater Manuf Process 31(3):352–358. https://doi.org/10.1080/10426914.2015.1058949

    Article  Google Scholar 

  10. Liu LM, Wang ZL, Zhang TY, Ba XL (2022) Analysis of metal transfer and weld forming characteristics in triple-wire gas indirect arc welding. Int J Adv Manuf Tech 120(9–10):6777–6788. https://doi.org/10.1007/s00170-022-09119-x

    Article  Google Scholar 

  11. Liu LM, Yu SB, Song G, Hu CH (2019) Analysis of arc stability and bead forming with high-speed TW-GIA welding. J Manuf Process 46:67–76. https://doi.org/10.1016/j.jmapro.2019.08.023

    Article  Google Scholar 

  12. Zhang Z, Wu DT, Zou Y (2018) Effect of bypass coupling on droplet transfer in twin-wire indirect arc welding. J Mater Process Tech 262:123–130. https://doi.org/10.1016/j.jmatprotec.2018.06.032

    Article  Google Scholar 

  13. Miao Y, Xu X, Wu B, Li X, Han D (2014) Effects of bypass current on the stability of weld pool during double sided arc welding. J Mater Process Tech 214(8):1590–1596. https://doi.org/10.1016/j.jmatprotec.2014.02.029

    Article  Google Scholar 

  14. Liu LM, Hu CH, Yu SB, Song G (2019) A triple-wire indirect arc welding method with high melting efficiency of base metal. J Manuf Process 44:252–260. https://doi.org/10.1016/j.jmapro.2019.05.022

    Article  Google Scholar 

  15. Liu LM, Yu SB, Hu CH (2019) Analysis of arc shape and weld forming in triple-wire indirect arc welding. Trans China Weld Inst 40(6):1–6

    Google Scholar 

  16. Wang ZL, Zhang TY, Dong XN, Liu LM (2022) Suppression of humping bead in high-speed triple-wire gas indirect arc welding. Int J Adv Manuf Tech. https://doi.org/10.1007/s00170-022-10031-7

    Article  Google Scholar 

  17. Ogino Y, Hirata Y, Kawata J, Nomura K (2013) Numerical analysis of arc plasma and weld pool formation by a tandem TIG arc. Weld World 57(3):411–423. https://doi.org/10.1007/s40194-013-0040-8

    Article  Google Scholar 

  18. Ding XP, Li H, Wei HL, Liu JQ (2016) Numerical analysis of arc plasma behavior in double-wire GMAW. Vacuum 124:46–54. https://doi.org/10.1016/j.vacuum.2015.11.006

    Article  Google Scholar 

  19. Wu XY, Tian RY, Zhang ZY, Li YA, Cheng J (2020) Study on the arcs interaction in plasma-GMAW hybrid welding. J Phys Conf Ser 1622(1):012030. https://doi.org/10.1088/1742-6596/1622/1/012030

    Article  Google Scholar 

  20. Wang L, Chen J, Jiang CL, Wu CS (2020) Numerical simulations of arc plasma under external magnetic field-assisted gas metal arc welding. Aip Adv 10(6):065030. https://doi.org/10.1063/5.0009935

    Article  Google Scholar 

  21. Shi L, Song YL, Xiao TJ, Ran GW (2012) Physical characteristics of welding arc ignition process. Chin J Mech Eng 25(4):786–791. https://doi.org/10.3901/CJME.2012.04.786

    Article  Google Scholar 

  22. Xiao X, Hua XM, Li F, Wu YX (2014) A modified Fowler-Milne method for monochromatic image analysis in multi-element arc plasma welding. J Mater Process Tech 14:1–28. https://doi.org/10.1016/j.jmatprotec.2014.05.026

    Article  Google Scholar 

  23. Xiao X, Hua X, Wu Y (2015) Comparison of temperature and composition measurement by spectroscopic methods for argon–helium arc plasma. Opt Laser Technol 66:138–145. https://doi.org/10.1016/j.optlastec.2014.08.017

    Article  Google Scholar 

  24. Zhu YL, Xu XK, Liu RT, Liu LM (2021) Magnetic-enhanced common conductive channel characteristics of two-electrode TIG. Int J Adv Manuf Tech 116:3217–3229. https://doi.org/10.1007/s00170-021-07674-3

    Article  Google Scholar 

  25. Valensi F, Pellerin S, Boutaghane A, Dzierzega K, Pellerin N, Briand F (2011) LTE experimental validation in a gas metal arc welding plasma column. Contrib Plasm Phsys 51(3):293–296. https://doi.org/10.1002/ctpp.201000061

    Article  Google Scholar 

  26. Sabbaghzadeh J, Dadras S, Torkamany M (2007) Comparison of pulsed Nd: YAG laser welding qualitative features with plasma plume thermal characteristics. J Phys D Appl Phys 40(4):1047–1051. https://doi.org/10.1088/0022-3727/40/4/019

    Article  Google Scholar 

  27. National Institute of Standards and Technology (2022) https://www.nist.gov/pml/atomic-spectra-database

  28. Liu LM, Chen MH (2011) Interactions between laser and arc plasma during laser–arc hybrid welding of magnesium alloy. Opt Laser Eng 49(9–10):1224–1231. https://doi.org/10.1016/j.optlaseng.2011.04.012

    Article  Google Scholar 

  29. Goldak J, Chakravarti A, Bibby M (1984) A new finite element model for welding heat sources. Metall Trans B 15(2):299–305. https://doi.org/10.1007/BF02667333

    Article  Google Scholar 

  30. Xu JL, Jing SX (1981) plasma physics. Atomic energy press, Beijing in Chinese

Download references

Funding

This work was supported by the National Natural Science Foundation of China (No. 52175290).

Author information

Authors and Affiliations

  1. Liaoning Key Laboratory of Advanced Welding and Joining Technology, School of Materials Science and Engineering, Dalian University of Technology, Dalian, 116024, China

    Liming Liu, Zeli Wang, Xinze Lv, Runtao Liu & Tianyi Zhang

Authors
  1. Liming Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zeli Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xinze Lv
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Runtao Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Tianyi Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Liming Liu: conceptualization, funding acquisition. Zeli Wang: operational experiments, methodology, writing-original draft, formal analysis. Xinze Lv: assist experiment, validation. Runtao Liu: language translation. Tianyi Zhang: data calculation.

Corresponding author

Correspondence to Liming Liu.

Ethics declarations

Ethical approval

The paper follows the guidelines of the Committee on Publication Ethics (COPE).

Consent to participate

The authors declare that they all consent to participate this research.

Consent for publication

The authors declare that they all consent to publish the manuscript.

Competing interests

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Liu, L., Wang, Z., Lv, X. et al. Analysis of conductive channel and heat transfer mechanism of triple-wire gas indirect arc welding. Int J Adv Manuf Technol 123, 1285–1296 (2022). https://doi.org/10.1007/s00170-022-10230-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10230-2

Keywords

Search

Navigation