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Stability and Heat Input Controllability of Two Different Modulations for Double-Pulse MIG Welding

School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510641, China
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Appl. Sci. 2019, 9(1), 127; https://doi.org/10.3390/app9010127
Received: 2 November 2018 / Revised: 20 December 2018 / Accepted: 21 December 2018 / Published: 1 January 2019
(This article belongs to the Special Issue Welding of Steels)
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Abstract

Aluminum alloy welding frequently experiences difficulties such as heat input control, poor weld formation, and susceptibility to pore generation. We compared the use of two different modulations for double-pulse metal inert gas (MIG) welding to reduce the heat input required to generate oscillations in the weld pool. The stabilities of rectangular wave-modulated and trapezoidal wave-modulated double-pulse MIG welding (DP-MIG and TP-MIG) were analyzed by examining their welding processes and weld profiles. We found that the transitional pulse in TP-MIG welding results in smoother current transitions, softer welding arc sounds, and a highly uniform fish-scale pattern. Therefore, TP-MIG welding is more stable than DP-MIG welding. The effects of these double-pulse modulation schemes on welding input energy are presented. We propose methods for reducing welding input energy by varying the number of pulses or the pulse base time of low-energy pulse train while keeping the welding current and welding arc stable and unchanged. Compared to DP-MIG welding, TP-MIG welding reduces the input energy by 12% and produces finer grain sizes, which increases weld hardness. Therefore, TP-MIG welding offers a new approach for heat input control in DP-MIG welding of aluminum alloys. The results of this work are significant for aluminum alloy welding. View Full-Text
Keywords: double-pulse MIG welding; rectangular waves; trapezoidal waves double-pulse MIG welding; rectangular waves; trapezoidal waves
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Xue, J.; Xu, M.; Huang, W.; Zhang, Z.; Wu, W.; Jin, L. Stability and Heat Input Controllability of Two Different Modulations for Double-Pulse MIG Welding. Appl. Sci. 2019, 9, 127.

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