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Gas Metal Arc Welding
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Gas Metal Arc Welding

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: closed (28 February 2017) | Viewed by 53256

Special Issue Editors

Dr. Hai-Lung Tsai

E-Mail Website
Guest Editor
Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO 65409-0500, USA
Interests: laser-material interactions; additive manufacturing
Special Issues, Collections and Topics in MDPI journals
Dr. Junling Hu

E-Mail Website
Guest Editor
Department of Mechanical Engineering, University of Bridgeport, Bridgeport, CT 06604, USA
Interests: gas metal arc welding; laser welding; additive manufacturing; electronics cooling
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Gas metal arc welding (GMAW) is the most widely used fusion joint process due to its many advantages, such as its suitability for most commercial metals and all weld positions, high quality weld, high welding speed, and suitability for automation.  GMAW is also a complex process, which involves interactions of arc plasma, metal transfer, weld pool dynamics and solidification, with simultaneous interaction of materials at the plasma, gaseous, and solid states. In addition to experimental study, numerical models have been developed to study a large number of complex phenomena in a GMAW process, including electromagnetics, heat transfer, fluid flow, metal transfer, microstructure evolution, and thermal mechanical effects. Both experimental study and numerical modeling of the GMAW process have significantly improved the understanding of the welding physics and help optimize welding process parameters and predict microstructure evolution and weld properties. With the advancement of the numerical modeling of the GMAW process, and the sensing and control of the welding process, real-time control of the GMAW process can be realized. GMAW has also been extended for more complex applications through digitally controlled power supplies, wire feeders, and gas regulation, such as welding automation, thin sheets, and dissimilar materials.

The Special Issue of the journal Applied Sciences, “Gas Metal Arc Welding”, aims to cover recent advances in the development of numerical modeling and experimental study of GMAW processes, sensing and control of GMAW processes, process optimization, and new applications of GMAW.

Dr. Hai-Lung Tsai
Dr. Junling Hu
Guest Editors

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Keywords

  • Gas metal arc welding
  • Arc plasma
  • Metal transfer
  • Weld pool dynamics
  • Arc sensing
  • Weld penetration control

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Published Papers (7 papers)

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Research

4073 KiB  
Article
Characteristics of GMAW Narrow Gap Welding on the Armor Steel of Combat Vehicles
by Jae-Seong Kim and Hui-Jun Yi
Appl. Sci. 2017, 7(7), 658; https://doi.org/10.3390/app7070658 - 27 Jun 2017
Cited by 10 | Viewed by 6305
Abstract
The primary purpose of this investigation was to study the characteristics of the armor steel weldment of combat vehicles by using GMAW narrow gap welding (NGW). The results showed that the mechanical properties and residual stress distribution of NGW weldment were improved, compared [...] Read more.
The primary purpose of this investigation was to study the characteristics of the armor steel weldment of combat vehicles by using GMAW narrow gap welding (NGW). The results showed that the mechanical properties and residual stress distribution of NGW weldment were improved, compared with conventional X-groove weldment. Additionally, ballistic tests according to MIL-HDBK-1941 were carried out to verify the ballistic ability of NGW weldment and the result showed that the NGW process was qualified for welding the armor steel of combat vehicle. Full article
(This article belongs to the Special Issue Gas Metal Arc Welding)
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2696 KiB  
Article
On the Visualization of Gas Metal Arc Welding Plasma and the Relationship Between Arc Length and Voltage
by Emanuel B. F. Dos Santos, Letícia H. Kuroiwa, A. Felipe C. Ferreira, Rob Pistor and Adrian P. Gerlich
Appl. Sci. 2017, 7(5), 503; https://doi.org/10.3390/app7050503 - 15 May 2017
Cited by 18 | Viewed by 7125
Abstract
In this article, the camera settings for high-speed imaging of the arc, metal transfer, and weld pool in gas metal arc welding (GMAW) are investigated. The results show that by only changing camera exposure times and the selection of narrow bandpass filters, images [...] Read more.
In this article, the camera settings for high-speed imaging of the arc, metal transfer, and weld pool in gas metal arc welding (GMAW) are investigated. The results show that by only changing camera exposure times and the selection of narrow bandpass filters, images that reveal features of the arc such as the iron vapor-dominated region, metal transfer and weld pool behavior can be produced without the need for external light sources. Using the images acquired, the arc length was measured and the relationship between arc length and arc voltage is discussed. The results show that for low values of current, the measured welding voltage increases with increasing arc length; however, for high current values, the arc voltage increases even though the measured arc length becomes shorter. It is suggested that the increase in arc voltage for high values of welding current is due to the increased evaporation of the wire electrode which decreases the plasma temperature and consequently the arc plasma electrical conductivity. Full article
(This article belongs to the Special Issue Gas Metal Arc Welding)
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17980 KiB  
Article
A Comparative Study of Additively Manufactured Thin Wall and Block Structure with Al-6.3%Cu Alloy Using Cold Metal Transfer Process
by Baoqiang Cong, Zewu Qi, Bojin Qi, Hongye Sun, Gang Zhao and Jialuo Ding
Appl. Sci. 2017, 7(3), 275; https://doi.org/10.3390/app7030275 - 10 Mar 2017
Cited by 147 | Viewed by 12044
Abstract
In order to build a better understanding of the relationship between depositing mode and porosity, microstructure, and properties in wire + arc additive manufacturing (WAAM) 2319-Al components, several Al-6.3%Cu deposits were produced by WAAM technique with cold metal transfer (CMT) variants, pulsed CMT [...] Read more.
In order to build a better understanding of the relationship between depositing mode and porosity, microstructure, and properties in wire + arc additive manufacturing (WAAM) 2319-Al components, several Al-6.3%Cu deposits were produced by WAAM technique with cold metal transfer (CMT) variants, pulsed CMT (CMT-P) and advanced CMT (CMT-ADV). Thin walls and blocks were selected as the depositing paths to make WAAM samples. Porosity, microstructure and micro hardness of these WAAM samples were investigated. Compared with CMT-P and thin wall mode, CMT-ADV and block process can effectively reduce the pores in WAAM aluminum alloy. The microstructure varied with different depositing paths and CMT variants. The micro hardness value of thin wall samples was around 75 HV from the bottom to the middle, and gradually decreased toward the top. Meanwhile, the micro hardness value ranged around 72–77 HV, and varied periodically in block samples. The variation in micro hardness is consistent with standard microstructure characteristics. Full article
(This article belongs to the Special Issue Gas Metal Arc Welding)
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6593 KiB  
Article
The Effect of EN Ratio and Current on Microstructural and Mechanical Properties of Weld Joined by AC-GMAW on Square Groove Butt Joints
by Adeel Ikram and Hyun Chung
Appl. Sci. 2017, 7(3), 261; https://doi.org/10.3390/app7030261 - 7 Mar 2017
Cited by 7 | Viewed by 8220
Abstract
In the present work, the effect of welding current and electrode negative (EN) ratio on microstructure and mechanical properties of square groove butt joint produced by alternating current gas metal arc welding (AC-GMAW) process has been investigated. The experiments were conducted using different [...] Read more.
In the present work, the effect of welding current and electrode negative (EN) ratio on microstructure and mechanical properties of square groove butt joint produced by alternating current gas metal arc welding (AC-GMAW) process has been investigated. The experiments were conducted using different combination of welding current ranging from 150 A to 250 A with three distinct EN ratios i.e., 0%, 30% and 50% on 5 mm thick steel plates at a constant joint gap of 1 mm and welding speed of 10 mm/s. The effect of current and EN ratio on welding soundness was evaluated through optical microscopy, tensile tests and micro-hardness mapping. The results revealed that, at higher values of currents, an increase in EN ratio resulted an increase in penetration depth. It was found that at a current of 250 A and a 50% EN ratio, the deep penetration was obtained. Tensile test results showed that the tensile strength properties improved with increasing current. Furthermore, the micro-hardness distribution was not strikingly affected by changing the EN ratio. Full article
(This article belongs to the Special Issue Gas Metal Arc Welding)
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3925 KiB  
Article
Research of a Multi-Frequency Waveform Control Method on Double-Wire MIG Arc Welding
by Ping Yao and Kang Zhou
Appl. Sci. 2017, 7(2), 171; https://doi.org/10.3390/app7020171 - 10 Feb 2017
Cited by 9 | Viewed by 4878
Abstract
To improve the energy efficiency and quality of the welding seam during the double-wire metal inert-gas (MIG) arc welding production, a new multi-frequency waveform control method was proposed in this paper. In this method, a multi-frequency modulation was added to the waveform in [...] Read more.
To improve the energy efficiency and quality of the welding seam during the double-wire metal inert-gas (MIG) arc welding production, a new multi-frequency waveform control method was proposed in this paper. In this method, a multi-frequency modulation was added to the waveform in the peak stage of trailing wire current, under the situation that the two wires current waveforms had the same frequencies but inverse phases. This new action can benefit the stability of welding process and improve the quality of welding seam. Actual experiments were conducted to validate the proposed method. Orthogonal experiments and corresponding mathematical analyses were also employed to seek an optimal parameters combination. Finally, an optimal combination was confirmed and a welding seam with satisfactory quality was obtained, which showed that the proposed control method and corresponding analyses can well serve the double-wire MIG arc welding, and then benefit the actual production in the future. Full article
(This article belongs to the Special Issue Gas Metal Arc Welding)
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7288 KiB  
Article
Analysis of Thermo-Elastic Fracture Problem during Aluminium Alloy MIG Welding Using the Extended Finite Element Method
by Kuanfang He, Qing Yang, Dongming Xiao and Xuejun Li
Appl. Sci. 2017, 7(1), 69; https://doi.org/10.3390/app7010069 - 12 Jan 2017
Cited by 13 | Viewed by 6505
Abstract
The thermo-elastic fracture problem and equations are established for aluminium alloy Metal Inert Gas (MIG) welding, which include a moving heat source and a thermoelasticity equation with the initial and boundary conditions for a plate structure with a crack. The extended finite element [...] Read more.
The thermo-elastic fracture problem and equations are established for aluminium alloy Metal Inert Gas (MIG) welding, which include a moving heat source and a thermoelasticity equation with the initial and boundary conditions for a plate structure with a crack. The extended finite element method (XFEM) is implemented to solve the thermo-elastic fracture problem of a plate structure with a crack under the effect of a moving heat source. The combination of the experimental measurement and simulation of the welding temperature field is done to verify the model and solution method. The numerical cases of the thermomechanical parameters and stress intensity factors (SIFs) of the plate structure in the welding heating and cooling processes are investigated. The research results provide reference data and an approach for the analysis of the thermomechanical characteristics of the welding process. Full article
(This article belongs to the Special Issue Gas Metal Arc Welding)
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Graphical abstract

8685 KiB  
Article
Modeling of Temperature Field during Multi-Pass GMAW Surfacing or Rebuilding of Steel Elements Taking into Account the Heat of the Deposit Metal
by Jerzy Winczek
Appl. Sci. 2017, 7(1), 6; https://doi.org/10.3390/app7010006 - 22 Dec 2016
Cited by 16 | Viewed by 7008
Abstract
This paper proposed an analytical model for describing the temperature field of multi-pass arc weld surfacing. The temperature field is described analytically assuming a bimodal volumetric model of the heat source and a semi-infinite body model of the (rebuilt) workpiece. The suggested analytical [...] Read more.
This paper proposed an analytical model for describing the temperature field of multi-pass arc weld surfacing. The temperature field is described analytically assuming a bimodal volumetric model of the heat source and a semi-infinite body model of the (rebuilt) workpiece. The suggested analytical solution takes into account the temperature changes caused not only by the direct heat of an electric arc, but also by the heat of the applied weld (melted metal of electrode). The solution considers temperature increments caused by overlaying consecutive welding sequences and by self-cooling of areas previously heated. Computations of the temperature field are carried out during the multi-pass gas metal arc welding (GMAW) surfacing of a steel plate. The results are presented in the form of transient and maximum (achieved in whole welding process) temperature distributions in the element’s cross-section, as well as thermal cycles at the selected point. Full article
(This article belongs to the Special Issue Gas Metal Arc Welding)
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