Cold wire gas metal arc welding (CW-GMAW) has been increasingly used in heavy-gauge manufacturing where high deposition rates are required. In such applications, the thermal efficiency of the CW-GMAW is crucial, yet it is not reported in the literature. Water calorimetry experiments were conducted to assess the thermal efficiency of CW-GMAW for two cold wire feed fractions and three common transfer modes: short circuit, globular, and spray, and these are compared to standard GMAW using the same transfer modes. The welds were produced using ER70S-6 as the electrode and cold wires. AISI 1020 plain carbon steel plates were used as the base metal with thicknesses of 9.53 mm and 6.35 mm. After producing the welds, three cross-sections were cut and analyzed using Vickers hardness maps, where differences were attributed to cooling variation rate across the weld cross-sections in high arc power samples. Results have shown that feeding a cold wire into the arc can re-introduce part of the lost heat back into the weld pool both in the short circuit and spray transfer regimes, suggesting an increase in the heat content in the weld pool.

在要求高沉积速率的大规格制造中，冷焊丝气体保护金属电弧焊（CW-GMAW）已被越来越多地使用。在此类应用中，CW-GMAW的热效率至关重要，但文献中未对此进行报道。进行了水量热实验，以评估两种冷焊丝进料部分和三种常见的传输方式（短路，球状和喷雾）的CW-GMAW的热效率，并使用相同的传输方式将其与标准GMAW进行比较。使用ER70S-6作为焊条和冷焊丝进行焊接。AISI 1020普通碳钢板用作基底金属，厚度为9.53 mm和6.35 mm。产生焊缝后，将三个横截面切割并使用维氏硬度图进行分析，其中差异归因于高电弧功率样品中整个焊缝横截面的冷却变化率。结果表明，将冷焊丝送入电弧可以在短路和喷雾传输方式下将一部分散失的热量重新引入焊接池，这表明焊接池中的热量增加。