Skip to main content
SpringerLink
Log in

An overview on the cold wire pulsed gas metal arc welding

  • Research Paper
  • Published:
Welding in the World Aims and scope Submit manuscript

Abstract

The demand to join newer and higher strength materials has motivated the development of controlled arc current waveforms in order to control deposition and heat input. Controlled waveforms in pulsed gas metal arc welding (P-GMAW) where the current is pulsed result in reduced nominal heat input, distortion, and residual stresses. A method to further improve these is by cold wire pulsed gas metal arc welding (CW-P-GMAW) to enhance P-GMAW with a cold wire (non-energized) fed into the weld pool. In this work, the feasibility of the process is reported and the influence of cold wire feeding on pulse parameters for low and high background to peak current ratios (Ib/Ip) were investigated through high-speed cinematography with synchronized current and voltage sampling; as well as evaluation of cross-sections via metallography. Moreover, it appears that the cold wire diminishes the heat transferred across the heat-affected zone (HAZ) for low current ratios.

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
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30

Similar content being viewed by others

References

  1. Yudodibroto BYB, Hermans MJM, Ouden G, Richardson IM (2013) Observations on droplet and arc behaviour during pulsed GMAW. Weld World 53:R171–R180. https://doi.org/10.1007/BF03266729

    Article  Google Scholar 

  2. Dos Santos EBF, Pistor R, Gerlich AP (2017) Pulse profile and metal transfer in pulsed gas metal arc welding: droplet formation, detachment and velocity. Sci Technol Weld Join 22:627–641. https://doi.org/10.1080/13621718.2017.1288889

    Article  CAS  Google Scholar 

  3. Dos Santos EBF, Pistor R, Gerlich AP (2017) High frequency pulsed gas metal arc welding (GMAW-P): the metal beam process. Manuf Lett 11:1–4. https://doi.org/10.1016/j.mfglet.2017.01.001

    Article  Google Scholar 

  4. Pal K, Pal SK (2011) Effect of pulse parameters on weld quality in pulsed gas metal arc welding: A review. J Mater Eng Perform 20:918–931. https://doi.org/10.1007/s11665-010-9717-y

    Article  CAS  Google Scholar 

  5. Ghosh PK (2017) Pulse current gas metal arc welding. Springer Singapore, Singapore, p 298

    Book  Google Scholar 

  6. Tong H, Ueyama T, Harada S, Ushio M (2001) Quality and productivity improvement in aluminium alloy thin sheet welding using alternating current pulsed metal inert gas welding system. Sci Technol Weld Join 6:203–208. https://doi.org/10.1179/136217101101538776

    Article  CAS  Google Scholar 

  7. Mohammadijoo M, Collins L, Henein H, Ivey DG (2017) Evaluation of cold wire addition effect on heat input and productivity of tandem submerged arc welding for low-carbon microalloyed steels. Int J Adv Manuf Technol 92:817–829. https://doi.org/10.1007/s00170-017-0150-3

    Article  Google Scholar 

  8. Pai A, Sogalad I, Basavarajappa S, Kumar P (2019) Results of tensile, hardness and bend tests of modified 9Cr 1Mo steel welds: comparison between cold wire and hot wire gas tungsten arc welding (GTAW) processes. Int J Press Vessel Pip 169:125–141. https://doi.org/10.1016/j.ijpvp.2018.12.002

    Article  CAS  Google Scholar 

  9. Häßler M, Rose S, Füssel U (2016) The influence of arc interactions and a central filler wire on shielding gas flow in tandem GMAW. Weld World 60:713–718. https://doi.org/10.1007/s40194-016-0337-5

    Article  Google Scholar 

  10. Xiang T, Li H, Huang CQ et al (2016) The metal transfer behavior and the effect of arcing mode on metal transfer process in twin-arc integrated cold wire hybrid welding. Int J Adv Manuf Technol:1–8. https://doi.org/10.1007/s00170-016-9451-1

    Article  Google Scholar 

  11. Ribeiro RA, dos Santos EBF, Assunção PDC et al (2015) Predicting weld bead geometry in the novel CW-GMAW process. Weld J 94:301s–311s

    Google Scholar 

  12. Cabral TS, Braga EM, Mendonça EAM, Scott A (2015) Influence of procedures and transfer modes in MAG welding in the reduction of deformations on marine structure panels. Weld Int 29:928–936. https://doi.org/10.1080/09507116.2014.932993

    Article  Google Scholar 

  13. Costa ES, Assunção PDC, Dos Santos EBF et al (2017) Residual stresses in cold-wire gas metal arc welding. Sci Technol Weld Join 22:706–713. https://doi.org/10.1080/13621718.2017.1306014

    Article  CAS  Google Scholar 

  14. Assunção PDC, Ribeiro RA, dos Santos EBF et al (2017) Feasibility of narrow gap welding using the cold-wire gas metal arc welding (CW-GMAW) process. Weld World 61:659–666. https://doi.org/10.1007/s40194-017-0466-5

    Article  CAS  Google Scholar 

  15. (2018) AISI 1020 Steel hot rolled

  16. AWS (2005) Specification for carbon steel electrodes and rods for gas shielded arc welding. American Welding Society (AWS), Miami

  17. Bosworth MR (1991) Effective heat input in pulsed current gas metal arc welding with solid wire electrodes. Weld J

  18. Electric L (2009) True energy TM instantaneous energy values for the weld. 1–4

  19. Carter R (2012) Analysis of pulsed gas metal arc welding (P-GMAW) heat input on UNS-S32101 lean duplex stainless steel. Arizona State University

  20. Soderstrom EJ, Mendez PF (2008) Metal transfer during GMAW with thin electrodes and Ar-CO 2. Weld Res 87:124–133

    Google Scholar 

  21. Melfi T (2010) New code requirements for calculating heat input. Wekding J 89:61–63

    Google Scholar 

  22. Dolby RE (1986) Guidelines for the classification of ferritic steel weld metal microstructural constituents using the light microscope. Weld World 24:144–148

    Google Scholar 

  23. Essers WG, Walter R (1981) Heat transfer and penetration mechanisms with GMA and plasma-GMA welding. Weld J 60:37–42

    Google Scholar 

  24. Mohammadijoo M, Kenny S, Collins L, Henein H, Ivey DG (2017) Influence of cold-wire tandem submerged arc welding parameters on weld geometry and microhardness of microalloyed pipeline steels. Int J Adv Manuf Technol 88:2249–2263. https://doi.org/10.1007/s00170-016-8910-z

    Article  Google Scholar 

  25. Liskevych O, Scotti A (2015) Determination of the gross heat input in arc welding. J Mater Process Technol 225:139–150. https://doi.org/10.1016/j.jmatprotec.2015.06.005

    Article  CAS  Google Scholar 

Download references

Acknowledgments

The authors would like to acknowledge TransCanada Pipelines, Inc. for the funding to perform this work. Mr. P.D.C. Assunção would like to thank the Coordination for Improvement of Higher Education Personnel (CAPES) for funding his visiting scholar research fellowship in the University of Waterloo.

Author information

Authors and Affiliations

  1. Centre for Advanced Materials Joining (CAMJ), University of Waterloo, 200 University Avenue West, Waterloo, ON, N2L 3G5, Canada

    R. A. Ribeiro & A. P. Gerlich

  2. Liburdi Automation Inc.—Liburdi GAPCO, 400 ON-6, Dundas, ON, L9H 7 K4, Canada

    P. D. C. Assunção & E. M. Braga

  3. Metallic Materials Characterization Laboratory (LCAM), Federal University of Pará (UFPA), Rua Augusto Corrêa, 1-Guamá, Belém, PA, 66075-110, Brazil

    E. B. F. Dos Santos

Authors
  1. R. A. Ribeiro
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. P. D. C. Assunção
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. E. B. F. Dos Santos
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. E. M. Braga
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. A. P. Gerlich
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to R. A. Ribeiro.

Additional information

Publisher’s note

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

Recommended for publication by Commission XII - Arc Welding Processes and Production Systems

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ribeiro, R.A., Assunção, P.D.C., Santos, E.B.F.D. et al. An overview on the cold wire pulsed gas metal arc welding. Weld World 64, 123–140 (2020). https://doi.org/10.1007/s40194-019-00826-w

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40194-019-00826-w

Keywords

Search

Navigation