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Heat input control in horizontal lap joint welding through active wire preheating in GMAW-P

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Abstract

In gas metal arc welding (GMAW) the arc power, in general, increases when the wire feed speed is increased. Thus, controlling heat input into the workpiece becomes a challenge, especially when trying to increase productivity. Metal transfer modes such as pulsed and controlled short circuit have been successfully applied to allow smooth metal transfer with relatively low energy. The effect of increasing the electrified length of the electrode or decreasing wire diameter in reducing current has been known for years. However, to some extent, this effect is limited to the physical conditions when using a large distance from contact tip to workpiece. To further increase melting efficiency and reduce arc power the torch presented in this paper includes a second electric circuit into GMAW to preheat the wire by ohmic heating before it reaches the main circuit. In this context, the objective of this work was to verify the effects of active wire preheating in GMAW in lap joint case in terms of electric signal behavior, thermal behavior in the plate, and weld bead formation. By increasing the preheating current, significant reduction in arc power was achieved. This reflects on the resulting weld by avoiding molten pool sagging, reducing fused area, silicate formation, and backside oxidation. The reduction in heat input resulted finally in a smaller heat affected zone which had a finer microstructure. In conclusion, the use of active wire preheating in GMAW expands the potential for increasing productivity and controlling heat input into the workpiece.

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Acknowledgements

The authors thank Linde’s Arc Technologies working team and Linde Technology management for the direct and indirect support through the conduction of this research.

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Authors and Affiliations

  1. Linde GmbH, Carl-Von-Linde Straße 25, 85716, Unterschleißheim, Germany

    Fernando Matos Scotti, Maximilian Pudenz, Sarah Perrin & Erwan Siewert

  2. Production Technology Group, Technische Universität Ilmenau, Gustav-Kirchhoff-Platz 2, 98693, Ilmenau, Germany

    Fernando Matos Scotti, Maximilian Pudenz & Jean Pierre Bergmann

  3. European School of Materials Science and Engineering, Université de Lorraine, 6 Rue Bastien Lepage, BP 630, 54010, Nancy, France

    Sarah Perrin

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  1. Fernando Matos Scotti
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  2. Maximilian Pudenz
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Correspondence to Fernando Matos Scotti.

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Scotti, F.M., Pudenz, M., Perrin, S. et al. Heat input control in horizontal lap joint welding through active wire preheating in GMAW-P. Weld World 68, 893–904 (2024). https://doi.org/10.1007/s40194-023-01654-9

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