Optimization of arc-start performance by wire-feeding control for GMA welding

The wire feeding system for gas metal arc welding usually consists of a wire feeder and a torch. In many industries, the distance between the wire feeder and the torch is generally 3 m to 5 m. In a conventional wire feeder, a direct current (DC) motor is used for wire feeding. However, a significant problem with this system is the impossibility of feedback control because of inner or outer impedance. In this paper, a digital wire feeder was developed by using a DC encoder motor and a push-pull torch. An optimized wire-feeding system was also developed by experiment. The welding process was observed using a high-speed camera. The resulting wire-feeding system exhibits low spatter generation and arc stability.

[1]  장희석,et al.  GMAW에서 와이어 송급속도의 변동이 아크안정성에 미치는 영향에 대한 연구 ( A Study on Effects of Wire Speed Fluctuation on Arc Stability in GMA Welding ) , 1995 .

[2]  Danut Iordachescu,et al.  Steps toward a new classification of metal transfer in gas metal arc welding , 2008 .

[3]  Bruce D. DeRuntz.  Assessing the Benefits of Surface Tension Transfer® Welding to Industry , 2003 .

[4]  N. Węglowski,et al.  Effect of welding current on metal transfer in GMAW , 2008 .

[5]  Tsuneo Mita,et al.  Quantitative estimates of arc stability for CO2 gas shielded arc welding , 1988 .

[6]  Rinsei Ikeda,et al.  Development of a low-spatter CO2 arc welding process with a high-frequency pulse current , 2009 .

[7]  김희진,et al.  기술보고 : CO2 용접에서 용접전원에 따른 스패터 발생량의 차이 ( The Characteristics of Power Sources on the Spatter Generation Rate in CO2 Are Welding Process ) , 1999 .

[8]  김희진,et al.  CO₂용접의 단락이행 조건에서 스패터 발생과 파형인자와의 관계 ( Relation between Spatter Generation and Waveform factor of CO₂Welding in Short-Circuit condition ) , 1998 .

[9]  E. Kannatey-Asibu,et al.  Observation of Arc Start Instability and Spatter Generation in GMAW : Spatter generation due to arc start instability was studied and a temperature model was developed to better understand electrode failure , 2008 .

[10]  H. Kim,et al.  Control Method of Arc Start for GMA Welding , 2009 .

[11]  Tsuneo Mita,et al.  Recent Advances in Welding Power Systems for Automated Welding , 1994 .

[12]  K Furukawa,et al.  New CMT arc welding process – welding of steel to aluminium dissimilar metals and welding of super-thin aluminium sheets , 2006 .

[13]  Sung-Chul Oh,et al.  A Review of Welding Current Waveform Control and Mechanical Control Technique for Reduction of Spatter in Short Circuit Transfer , 2007 .

[14]  Sato Masaharu,et al.  Waveform control in gas shielded arc welding , 1988 .

[15]  T Yasuda,et al.  The development of welding current control systems for spatter reduction , 1990 .

[16]  Hideyuki Yamamoto,et al.  Recent advances in inverter controlled arc welding power sources and their application. , 1989 .