Article
Materials Science, Multidisciplinary
Shinichi Tashiro, Sarizam Bin Mamat, Anthony B. Murphy, Toshifumi Yuji, Manabu Tanaka
Summary: This study clarifies the effect of plasma on the metal transfer process in plasma MIG welding through numerical analysis. The presence of plasma reduces current density and droplet temperature, resulting in decreased fume formation. The dispersion of arc attachment leads to a lower current density, larger droplet diameter, and smaller metal transfer frequency.
Article
Optics
Yazhou Jia, Tao Wen, Ning Huang, Junlin Zhang, Jun Xiao, Shujun Chen, Wenhao Huang
Summary: Using 2219 aluminum alloy as the base metal, a high frequency and low power pulsed laser MIG hybrid welding system was established to analyze and compare the effects of the high-frequency and low-power pulsed laser on the arc shape, metal transfer behavior, and weld formation in the hybrid welding process. The addition of laser irradiation reduced the welding current and improved the stability of the welding process, resulting in uniformly formed weld seams and reduced pore defects.
OPTICS AND LASER TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Kazuya Ishida, Shinichi Tashiro, Kazufumi Nomura, Dongsheng Wu, Manabu Tanaka
Summary: This study investigates the mechanism of arc coupling in plasma-MIG hybrid welding through tomographically spectroscopic measurement. The results show that the arc coupling strongly depends on the waveform of the arc current and is governed by the balance between stiffness and deflection of the arcs.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Thermodynamics
Dongsheng Wu, Kazuya Ishida, Shinichi Tashiro, Kazufumi Nomura, Xueming Hua, Ninshu Ma, Manabu Tanaka
Summary: A paraxial hybrid plasma-MIG welding process has been developed for joining middle-thick high strength steel plates. The study investigates the characteristics of the arc and metal vapor using an advanced three-dimensional spectroscope measurement system. The dynamic behaviors of the keyhole and element mixing are studied using a three-dimensional numerical model. The experimental and numerical results reveal that the Fe vapor ejected from the wire surface, along with the butting gap, significantly influence the arc characteristics, keyhole stability, molten metal flow, and element mixing.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2023)
Review
Thermodynamics
Jie Yang, Shichang Xu, Chuanbao Jia, Yanfei Han, Sergii Maksymov, Chuansong Wu
Summary: In this paper, a non-axisymmetric three-dimensional numerical model was developed to simulate the typical globular repelled transfer process with large droplets in underwater wet flux-cored wire arc welding. The results showed that the droplet movement was affected by multiple forces, including gravity, surface tension, self-induced electromagnetic force, gas flow, and force from metal evaporation. The simulated values from the numerical model were in good agreement with the experimental ones.
INTERNATIONAL JOURNAL OF THERMAL SCIENCES
(2023)
Article
Thermodynamics
Xin Li, Suning Zhao, Laihege Jiang, Yang Lu, Mengcheng Gong, Chen Zhang, Ming Gao
Summary: Current studies have shown that laser-arc interaction affects droplet transfer behaviors. This study quantitatively analyzed the effects of laser power on droplet transfer frequency, detachment time, and motion behaviors in laser-MIG hybrid welding of aluminum alloy. The results revealed that the droplet growth and detachment in hybrid welding was accelerated by 22%, while the droplet flight motion was prolonged by 36% at maximum. The mechanism of these effects was discussed based on droplet force analysis.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2023)
Article
Materials Science, Multidisciplinary
Xuefei Cui, Ji Chen, Chunyang Xia, Xiaohui Han, Hao Su, Chuansong Wu
Summary: TIG-MIG hybrid welding combines the advantages of TIG welding and MIG welding, effectively enhancing welding quality and productivity. A three-dimensional transient model was established to investigate the arc-droplet-weld pool behavior in TIG-MIG hybrid welding. Simulation and analysis revealed that the introduction of TIG arc decreased metal vapor content and increased arc temperature.
Article
Automation & Control Systems
Hsuan-Liang Lin, Guan-Ching Chen, Ching-Min Cheng
Summary: The novel plasma-MIG hybrid welding process improves the efficiency and reduces defects in welding aluminum alloy thick plates. The study investigates the effects of different welding parameters on the penetration capability, tensile strength, microstructure, and hot cracking susceptibility. The results show that selecting the appropriate plasma arc current, torch travel speed, and plasma arc argon flow rate significantly affects the welding quality.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Baihao Cai, Juan Fu, Yong Zhao, Fugang Chen, Yonghui Qin, Shuming Song
Summary: This study investigated the morphological characteristics of arc plasma and droplet transfer during the alternating magnetic field-assisted narrow gap groove laser-MIG hybrid welding process. It was found that the magnetic field improved arc stability, promoted droplet transfer, decreased droplet diameter, and increased weld bead width while reducing pores in the weld.
Article
Automation & Control Systems
Insa Henze, Peer Woizeschke
Summary: The presence of metal vapor affects the stability of arc in arc and hybrid welding. The composition of the metal vapor and the substrate material composition play a key role due to different ionization energies of the material elements. A special setup is used to investigate the influence of metal vapor on the behavior of a vertically oriented arc generated by a separate laser-induced vapor generation welding process. Experimental results show that the arc voltage increases under the presence of metal vapor, leading to a decrease in arc stability.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Ziran Wang, Yugang Miao, Ji Liu, Yuyang Zhao, Yifan Wu, Qingwen Deng
Summary: This research proposes a method for joining AA 5083 aluminum alloy using pulse current mode in bypass-current plasma-GMAW hybrid arc welding. The effects of multiple pulse currents on metal droplet behaviors were comprehensively studied through experiments and simulations. The results show that the use of pulse waveform increases the transfer frequency and stability of the droplets, providing an optimized method for controlling metal droplet behaviors in aluminum alloy welding.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Optics
Fuyun Liu, Biao Yang, Haofeng Sun, Houqin Wang, Caiwang Tan, Guodong Wang, Bo Chen
Summary: This study investigates the influence of laser power on droplet transfer in laser-MIG hybrid welding. The results indicate that increasing laser power can improve the transfer frequency, but it decreases once the power exceeds a critical value. Considering factors such as laser source characteristics, materials, laser focusing distance, and laser-arc distance, these findings provide guidance for optimizing welding processes, improving weld quality, and preventing spatters.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Yanqiu Li, Zhi Cheng, Sihua Liu, Chunhuan Chen, Ruiming Ren, Jing Wen
Summary: In this paper, interrupted pulsed arc welding (IPAW) was used to join TC4 and 304SS dissimilar metals, successfully preventing the formation of brittle Ti-Fe intermetallic compounds. By precisely regulating the arc pulsed time, a joint without the TiFe2 phase was created, and a Ti-rich reaction layer was formed, resulting in a high shear strength.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Materials Science, Multidisciplinary
Jie Xu, Yiming Ma, Lin Wang, Yiran Zhang, Xu Lu
Summary: A numerical model was established to investigate the influence of the welding current on the fluid flow of arc plasma and filler metal in pulsed gas metal arc welding (P-GMAW). Experimental results showed that the waveform with a median current of 140 A had the best tolerance of the welding speed. Numerical simulation results revealed that this waveform could lead to lower droplet temperature and velocity.
Review
Materials Science, Multidisciplinary
Jeyaganesh Devaraj, Aiman Ziout, Jaber E. Abu Qudeiri
Summary: Gas Metal Arc Welding (GMAW) technology has expanded in various areas in recent years, but faces challenges in selecting appropriate welding parameters, particularly in dissimilar metal welding. This paper surveyed different GMAW standards to select suitable parameters for welding dissimilar nonferrous metals, and explored advancements in GMAW for non-ferrous welding. By controlling heat input and post-heat treatments, adequate joint properties can be achieved to widen the utilization scope of GMAW in automated large-scale manufacturing.