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Aluminum gas metal arc welding (GMAW) uses inert shielding gas to minimize weld pool oxidation and reduce susceptibility to porosity and lack of fusion defects. For aluminum shipbuilding, Naval requirements highly recommend the use of helium – argon mixtures or 100% (pure) helium shielding gas to provide a broader heat field and ensure proper weld fusion, particularly at the weld toes. Pure argon shielding gas can be used but it has proven to be susceptible to lack of fusion and porosity defects, particularly in thick sections that pose a large heat sink where argon’s lower thermal conductivity promotes a narrower arc heat field and poorer weld penetration. The continued use of helium is a concern because it’s a finite resource that costs approximately 5 times argon. In this study, the rotating electrode pulsed gas metal arc welding (REP-GMAW) process was investigated as a way to solve the argon shielding fusion problem, mitigate helium consumption, and provide shipbuilding cost savings. The target application was horizontal and vertical erection butt joints made from 5083 aluminum plate. An advanced REP-GMAW torch was used that permitted the evaluation of a range of electrode spin diameters and frequencies. Compared to torch weaving at a couple hertz, the arc heat field and bead shape can be more effectively changed since the rotation speeds can be up to 5,000 rotations per minute (~83 hertz). A series of bead on plate tests were used to evaluate the relationship between ER5183 electrode rotation parameters and arc power on constant deposit area bead shape. These tests were compared to stringer beads (no oscillation) that were made with argon, helium, and helium-argon shielding gases. Preferred rotating electrode parameter relationships were developed with pure argon for producing weld beads that had underbead fusion profiles that were equivalent to helium-based weld deposits. For preferred deposit sizes for groove welding, preferred bead shape welds were achieved when electrode spin frequency was 50 spins per inch and rotation diameter setting of 2. The second part of the study developed rotating electrode GMA-P welding procedures for 17-mm V-groove butt joints with ceramic backing in both the horizontal and vertical position. The REP-GMAW process was found to improve joint fusion and out of position deposition rate. By distributing the heat, the rotating arc weld pool showed better stability compared to stringer beads, especially in the horizontal position for making the root pass on ceramic, and then multiple fill passes to complete the joint. Deposition rates were up to 5.16 pounds / hour which is very good for aluminum erection welding. Based on this study, REP-GMAW using pure argon shielding gas is a suitable replacement for traditional GMAW of aluminum using pure helium or helium – argon mixtures Future studies with REP-GMAW should investigate bead shape and productivity improvements when welding with other alloys commonly used in shipbuilding. In addition, future studies should explore REP-GMAW arc physics and the interactions between the rotating electrode and the weld puddle.
Advancements in Intelligent Gas Metal Arc Welding Systems: Fundamentals and Applications presents the latest on gas metal arc welding which plays a significant role in modern manufacturing industries and accounts for about 70% of welding processes. The importance of advancements in GMAW cannot be underestimated as they can lead to more efficient production strategies, resource savings and quality improvements. This book provides an overview of various aspects associated with GMAW, starting from the theoretical basis and ending with characteristics of industrial applications and control methods. Additional sections cover processes associated with welding and welding control, such as fuzzy logic, artificial neural networks, and others. Provides an up-to-date overview of recent GMAW developments Includes insights into intelligent welding automation Describes real-world, industrial cases of welding automation implementation
Pulsed-current is used primarily with the gas tungsten-arc and gas metal-arc welding processes and, to a limited degree, with plasma-arc welding. The pulsed-current arc welding processes employ two levels of welding current instead of the single level that is used conventionally. Welding current is, in effect, switched between a high and a low level to produce a 'pulsating' current or welding arc. Pulsed-current processes offer important advantages, including, among others, improved control of welding heat input rates, reduced distortion of the parts during welding, improved weld quality, and improved control of weld metal deposition in all welding positions. Pulsed-current gas tungsten-arc (PC-GTA) and pulsed-current gas metal-arc (PC-GMA) welding processes have been used for joining a variety of materials, including some that are often considered difficult-to-weld materials. The memorandum reviews the available literature that has been published on pulsed-current arc welding processes. In addition, information was obtained from numerous representatives of pulsed-current equipment manufacturers and users. (Author).
Hybrid laser-arc welding (HLAW) is a combination of laser welding with arc welding that overcomes many of the shortfalls of both processes. This important book gives a comprehensive account of hybrid laser-arc welding technology and applications. The first part of the book reviews the characteristics of the process, including the properties of joints produced by hybrid laser-arc welding and ways of assessing weld quality. Part two discusses applications of the process to such metals as magnesium alloys, aluminium and steel as well as the use of hybrid laser-arc welding in such sectors as ship building and the automotive industry. With its distinguished editor and international team of contributors, Hybrid laser-arc welding is a valuable source of reference for all those using this important welding technology. Reviews arc and laser welding including both advantages and disadvantages of the hybrid laser-arc approach Explores the characteristics of the process including the properties of joints produced by hybrid laser-arc welding and ways of assessing weld quality Examines applications of the process including magnesium alloys, aluminium and steel with specific focus on applications in the shipbuilding and automotive industries
Within manufacturing, welding is by far the most widely used fabrication method used for production, leading to a rise in research and development activities pertaining to the welding and joining of different, similar, and dissimilar combinations of the metals. This book addresses recent advances in various welding processes across the domain, including arc welding and solid-state welding process, as well as experimental processes. The content is structured to update readers about the working principle, predicaments in existing process, innovations to overcome these problems, and direct industrial and practical applications. Key Features: Describes recent developments in welding technology, engineering, and science Discusses advanced computational techniques for procedure development Reviews recent trends of implementing DOE and meta-heuristics optimization techniques for setting accurate parameters Addresses related theoretical, practical, and industrial aspects Includes all the aspects of welding, such as arc welding, solid state welding, and weld overlay
This book, a unique text on robotics and welding, will be bought by graduate students, and researchers and practitioners in robotics and manufacturing.