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Power-arc model based adaptive arc length control of P-GMAW for Al–Mg alloy

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Abstract

It is essential to understand the power-arc model and the relationship of various parameters in pulsed gas metal arc welding (P-GMAW) process, in order to obtain stable arc length and droplet transfer. In this study, we analyzed the linear model of the GMAW process with some reasonable assumptions. A mathematical power-arc model of P-GMAW was established through an experimental statistical method by using a commercial welding power supply. Then, the mathematical model was applied combined with the adaptive arc length control strategy in the P-GMAW process of Al–Mg alloy by using the self-developed welding power supply. The experimental results indicated that the arc length of P-GMAW process for Al–Mg alloy kept uniform when using the experimental mathematical model and adaptive arc length control strategy. One drop per pulse (ODPP) droplet transfer mode was observed without spatters and cracks by carefully designing the preset parameters. The adaptive arc length control strategy showed good feasibility in Al–Mg alloy welding.

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Funding

This work was supported by the National Natural Science Foundation of China (Grant No. 52105374) and Startup Fund for Young Faculty at SJTU (Grant No. 22X010503455). Qiang Wang has received these research supports.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Qiang Wang, Yanling Xu & Huajun Zhang

  2. School of Mechanical Engineering and Automation, Beihang University, Beijing, 100191, China

    Bojin Qi

  3. Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

    Aiping Wu & Yue Zhao

  4. Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Tsinghua University, Beijing, 100084, China

    Aiping Wu

  5. State Key Laboratory of Tribology, Tsinghua University, Beijing, 100084, China

    Aiping Wu

  6. State Key Laboratory of Clean and Efficient Turbomachinery Power Equipment, Tsinghua University, Beijing, 10084, China

    Yue Zhao

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  1. Qiang Wang
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  2. Bojin Qi
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  3. Yanling Xu
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  4. Aiping Wu
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Contributions

Qiang Wang: investigation, analysis, funding acquisition, writing — original draft. Bojin Qi: supervisor, conceptualization, writing—original draft. Yanling Xu: welding experiment, data curation. Aiping Wu: methodology. Yue Zhao: visualization, writing — review and editing. Huajun Zhang: methodology, writing — review and editing. All authors read and approved the final manuscript.

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Correspondence to Yue Zhao or Huajun Zhang.

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Wang, Q., Qi, B., Xu, Y. et al. Power-arc model based adaptive arc length control of P-GMAW for Al–Mg alloy. Int J Adv Manuf Technol 128, 639–651 (2023). https://doi.org/10.1007/s00170-023-11814-2

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  • DOI: https://doi.org/10.1007/s00170-023-11814-2

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