Determination of equilibrium wire-feed-speeds for stable gas metal arc welding

Z. H. Rao, Jun Zhou, H. L. Tsai

Research output: Contribution to journalArticle

9 Citations (Scopus)

Abstract

In gas metal arc welding (GMAW), a consumable electrode wire is fed normally at a pre-determined constant speed in order to achieve a stable welding process for given welding conditions. In this article, a comprehensive mathematical model for GMAW was employed to study the interplay among electrode melting; the formation, detachment, and transfer of droplets; and the plasma arc under various welding conditions. It is found that a stable GMAW process can be obtained through a balance between the wirefeed- speed (WFS) and the dynamic electrode melting rate due to the transient behavior of plasma arc. Otherwise, an unstable welding process including electrode burned-back or stick-onto the weld pool could occur. The model-predicted equilibrium WFS varying with welding current and feeding-wire diameter is in good agreement with the published empirical results obtained through a trial-and-error procedure.

Original languageEnglish (US)
Pages (from-to)6651-6664
Number of pages14
JournalInternational Journal of Heat and Mass Transfer
Volume55
Issue number23-24
DOIs
StatePublished - Jan 1 2012

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arc welding
Gas metal arc welding
welding
Welding
wire
Wire
gases
Electrodes
electrodes
metals
plasma jets
Melting
melting
Plasmas
detachment
mathematical models
Welds
Mathematical models

All Science Journal Classification (ASJC) codes

  • Condensed Matter Physics
  • Mechanical Engineering
  • Fluid Flow and Transfer Processes

Cite this

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abstract = "In gas metal arc welding (GMAW), a consumable electrode wire is fed normally at a pre-determined constant speed in order to achieve a stable welding process for given welding conditions. In this article, a comprehensive mathematical model for GMAW was employed to study the interplay among electrode melting; the formation, detachment, and transfer of droplets; and the plasma arc under various welding conditions. It is found that a stable GMAW process can be obtained through a balance between the wirefeed- speed (WFS) and the dynamic electrode melting rate due to the transient behavior of plasma arc. Otherwise, an unstable welding process including electrode burned-back or stick-onto the weld pool could occur. The model-predicted equilibrium WFS varying with welding current and feeding-wire diameter is in good agreement with the published empirical results obtained through a trial-and-error procedure.",
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Determination of equilibrium wire-feed-speeds for stable gas metal arc welding. / Rao, Z. H.; Zhou, Jun; Tsai, H. L.

In: International Journal of Heat and Mass Transfer, Vol. 55, No. 23-24, 01.01.2012, p. 6651-6664.

Research output: Contribution to journalArticle

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