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Analysis of Metal Transfer Characteristics in Low-Heat Input Gas Metal Arc Welding of Aluminum Using Aluminum–Silicon Alloy Fillers
Metallurgical and Materials Transactions B ( IF 2.4 ) Pub Date : 2022-06-16 , DOI: 10.1007/s11663-022-02574-7
Divya Nalajala , Rama Kishore Mookara , Murugaiyan Amirthalingam

Welding of thin aluminum sheets with high heat input conventional welding processes often results in heat-affected zone softening, distortion, and burn-through problems. In this study, metal transfer characteristics are optimized in a gas metal arc-welding process to achieve low heat input and high productivity to weld aluminum sheets. The main objective of this study is to achieve maximum droplet transfer rate at low heat input in AA 1050 alloy using short circuiting (CMT) and short circuiting with pulse (CMT-P) gas metal arc-welding processes. Metal transfer characteristics are studied while depositing the AlSi5 and AlSi12 fillers on to an AA 1050 aluminum plate. Experiments are conducted to investigate the influence of mean current (90 to 110 A) and pulse frequency (5, 6, and 7) on heat input, droplet transfer rate, and its diameter. Kinetics of the metal transfer during welding is correlated with the corresponding current and voltage waveform and bead geometry. Results showed that for a given heat input, the droplet transfer rate is high in CMT-P at all mean current amplitudes compared to short-circuiting process for both the fillers. Analysis of the bead geometry indicated that for a given mean current, bead width of the AlSi12 filler is always higher than the AlSi5 filler in both the modes of metal transfer due to the near complete eutectic solidification in the former case. It is also found that the filler wire composition does not affect the droplet transfer rate for a given mean current in CMT and CMT-P processes used in this study.



中文翻译:

铝硅合金填料低热输入气体金属电弧焊铝的金属转移特性分析

使用高热输入传统焊接工艺焊接薄铝板通常会导致热影响区软化、变形和烧穿问题。在这项研究中,在气体保护金属电弧焊接工艺中优化了金属传递特性,以实现低热输入和高生产率来焊接铝板。本研究的主要目的是使用短路 (CMT) 和脉冲短路 (CMT-P) 气体金属电弧焊接工艺在 AA 1050 合金中实现低热输入下的最大熔滴传输速率。在将 AlSi5 和 AlSi12 填料沉积到 AA 1050 铝板上时研究了金属转移特性。进行实验以研究平均电流(90 至 110 A)和脉冲频率(5、6 和 7)对热输入、液滴传输速率及其直径的影响。焊接过程中金属转移的动力学与相应的电流和电压波形以及焊道几何形状相关。结果表明,对于给定的热输入,与两种填料的短路过程相比,在所有平均电流幅度下,CMT-P 中的液滴转移速率都很高。焊道几何形状分析表明,对于给定的平均电流,由于在前一种情况下几乎完全共晶凝固,在两种金属转移模式下,AlSi12 填料的焊道宽度总是高于 AlSi5 填料。还发现,在本研究中使用的 CMT 和 CMT-P 工艺中,对于给定的平均电流,填充焊丝成分不会影响液滴转移速率。结果表明,对于给定的热输入,与两种填料的短路过程相比,在所有平均电流幅度下,CMT-P 中的液滴转移速率都很高。焊道几何形状分析表明,对于给定的平均电流,由于在前一种情况下几乎完全共晶凝固,在两种金属转移模式下,AlSi12 填料的焊道宽度总是高于 AlSi5 填料。还发现,在本研究中使用的 CMT 和 CMT-P 工艺中,对于给定的平均电流,填充焊丝成分不会影响液滴转移速率。结果表明,对于给定的热输入,与两种填料的短路过程相比,在所有平均电流幅度下,CMT-P 中的液滴转移速率都很高。焊道几何形状分析表明,对于给定的平均电流,由于在前一种情况下几乎完全共晶凝固,在两种金属转移模式下,AlSi12 填料的焊道宽度总是高于 AlSi5 填料。还发现,在本研究中使用的 CMT 和 CMT-P 工艺中,对于给定的平均电流,填充焊丝成分不会影响液滴转移速率。由于在前一种情况下几乎完全共晶凝固,在两种金属转移模式下,AlSi12 填料的焊道宽度总是高于 AlSi5 填料。还发现,在本研究中使用的 CMT 和 CMT-P 工艺中,对于给定的平均电流,填充焊丝成分不会影响液滴转移速率。由于在前一种情况下几乎完全共晶凝固,在两种金属转移模式下,AlSi12 填料的焊道宽度总是高于 AlSi5 填料。还发现,在本研究中使用的 CMT 和 CMT-P 工艺中,对于给定的平均电流,填充焊丝成分不会影响液滴转移速率。

更新日期:2022-06-16
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