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Pulsed dynamic wire feeding with low insertion angle in GTAW process: a metal transfer characterization

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Abstract

Strategies for wire feeding in the GTAW process have evolved considerably in the last few years with the development of new techniques and wire feed systems. Nowadays, the most advanced technologies make use of dynamic wire feeding techniques. In this context, the aim of this study was to analyze the pulsed dynamic wire feeding technique with a low insertion angle between the wire and the tungsten electrode, in order to characterize aspects of the GTAW process variant such as metal transfer, temperature distribution, and weld geometry. A setup of GTAW equipment (power source, wire feeder, and welding torch) was coupled to an anthropomorphic robot for the torch displacement, and pulsed welding current was used. A multiple output analysis was applied: electric signal acquisition, infrared thermography filming, high speed filming, and macrographic analysis. Results show that the variation of the frequency together with the wire feed system dynamics influence the metal transfer events. At frequencies of 5, 15, and 20 Hz, for instance, the intermittent bridge transfer was not synchronized with the current pulsation, but at 10 Hz the metal transfer was well defined and occurred at the same frequency as the welding current pulse. The results also show that a frequency variation does not influence the weld bead temperature distribution, but for the wire feeding in the background period series, the weld bead penetration was higher than the other series.

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Acknowledgements

The research presented in this paper is being conducted within the LABSOLDA — Welding and Mechatronics Institute, from Federal University of Santa Catarina, Brazil. The authors are grateful to PETROBRAS and to the Brazilian government agencies CNPq and CAPES for promoting and funding this work.

Funding

This work is funded by CNPq, CAPES and PETROBRAS.

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Authors and Affiliations

  1. Department of Mechanical Engineering, LABSOLDA — Welding and Mechatronics Institute, Federal University of Santa Catarina, Florianopolis, Santa Catarina, Brazil

    Ivan Olszanski Pigozzo, Régis Henrique Gonçalves e Silva, Daniel Galeazzi & Alex Sandro Pereira

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  1. Ivan Olszanski Pigozzo
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  2. Régis Henrique Gonçalves e Silva
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  3. Daniel Galeazzi
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  4. Alex Sandro Pereira
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Contributions

Ivan O. Pigozzo: conceptualization, data collection, formal analysis and investigation, writing.

Régis H. G. e Silva: conceptualization, writing, review.

Daniel Galeazzi: formal analysis and investigation, writing.

Alex S. Pereira: formal analysis and investigation, writing.

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Correspondence to Ivan Olszanski Pigozzo.

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The authors declare no competing interests.

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Recommended for publication by Commission XII—Arc Welding Processes and Production Systems.

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Pigozzo, I.O., e Silva, R.H.G., Galeazzi, D. et al. Pulsed dynamic wire feeding with low insertion angle in GTAW process: a metal transfer characterization. Weld World 66, 2107–2118 (2022). https://doi.org/10.1007/s40194-022-01352-y

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  • DOI: https://doi.org/10.1007/s40194-022-01352-y

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