Abstract
Wire feed rate plays a vital role in determining the weld characteristics in gas metal arc welding (GMAW). The wire feed rate is affected by any change in welding current in the case of steady current GMA welding and by any change in frequency, peak current, base current and duration of peak and base currents in the case of pulsed GMA welding. To predict the wire feed rate for any set of these parameters, a mathematical model was developed from the results obtained by conducting experiments. Electrode resistance heating constant and arc resistance heating constant were also determined by fitting a regression model. The above parametric constants have been used to simulate the wire feed rates for pulsed GMA welding for different pulse parameters using MATLAB. The effects of pulse parameters on the burnoff factor and burnoff rates were also analysed. The investigation was carried out using AWS 5.22–95 filler wire of size 1.2 mm diameter and the base metal used was IS:2062 structural steel plate of 20 mm thickness. An argon and 5% CO2 gas mixture at a flow rate of 16 l/min was used for shielding throughout the welding.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Boughton, Lucey JA (1965) The use of pulsed current to control metal transfer in welding. Br Weld J 4:159–166
Allum CJ (1983) MIG welding—time for a reassessment. Met Constr, June 347–353
Needham JC (1965) Pulse controlled consumable electrode welding arcs—general principles and operating characteristics. Br Weld J 4:191–197
Rajasekaran S (1999) Weld bead characteristics in pulsed GMA welding of Al-Mg alloys. Weld J 78(12):397–407
Amin M (1983) Pulse current parameters for arc stability and controlled metal transfer in arc welding. Met Constr, May 272–377
Stanzel K (2001) Pulsed GMAW cuts cycle time by 600 percent. Weld Design Fabr, April 85–87
Jilong M, Apps RL (1983) New MIG process results from metal transfer mode control. Weld Met Fabr, May 168–175
Raja A (1998) Flux core stelliting by pulsed MAG welding. WRI J 19(3):98–101
Elliott Sue (1985) Using synergic MIG successfully. Met Constr, March 148–151
Rajasekaran S (2000) Surface topography of pulsed current gas metal arc clads. Surf Eng 16(6):495–500
Vilarinho LO, Scotti A (2000) An alternate algorithm for synergic pulsed GMAW of aluminum. Aust Weld J 45:36–44
Weber Jeff (1982) Pulsed GMAW a plus for midwestern metal worker. Weld J 62(11):51–52
Essers WG, Van Gompal (1984) Arc control with pulsed GMA welding. Weld J 64(6):26–32
Bosworth MR (1991) Effective heat input in pulsed gas metal arc welding with solid wire electrodes. Weld J 70(5):111-s–117-s
Kim YS, Eagar TW (1993) Metal transfer in pulsed current gas metal arc welding. Weld J 72(7):279–287
Ghosh PK, Gupta PC (1996) Use of pulse current MIG welding improves the weld characteristics of Al-Zn-Mg Alloy. Indian Weld J, April 24–32
McGlone (1982) Weld bead geometry prediction—a review. Metal Constr, July 378–384
Pixley M, Kemppi (1989) Power sources for pulsed MIG welding. Joining and Materials, June 268–271
Norrish J (1987) What is synergic MIG? Weld Met Fabr 227–232, July
Rajasekaran S, Kulkarni SD et al (1998) Droplet detachment and plate fusion characteristics in pulsed current gas metal arc welding. Weld J 77(6):254–269
Subramaniam S, White DR, Jones JE, Lyons DW (1999) Experimental approach to selection of pulsing parameters in pulsed GMAW, AWS. Weld J 78(5):166–172
Smati Z (1986) Automatic pulsed MIG welding. Met Constr, Jan 38R–44R
French IE, Bosworth MR (1995) A comparison of pulsed and conventional welding with basic flux cored and metal cored welding wires. Weld J 74(6):197–205
Cornu J (1988) Advanced welding systems: consumable electrode processes. IFS, United Kingdom
Rajasekaran S (1997) Method of selecting the most suitable combination of parameters in pulsed current gas metal arc welding process. Proceedings of the international conference on advances in mechanical and industrial engineering, Roorkee, India, 6–8 Feb, pp 1115–1122
Collard JF (1998) Adaptive pulsed GMAW control: the digipulse system. Weld J 77(11):35–38
Murray PE (2002) Selecting parameters for GMAW using dimensional analysis. Weld J 81(7):125–131
Kim IS, Son KJ, Yang YS, Yaragada PKDV (2003) Sensitivity analysis for process parameters in GMA welding process using a factorial design method. Int J Mach Tools Manuf 43:763–769
Ramasamy S et al (2002) Design of experiments study to examine the effect of polarity on stud welding. Weld J 81(2):19–26
Gosh PK, Gupta PC, Goyal VK (1998) Stainless steel cladding of structural steel plate using the pulsed current GMAW process. Weld J 77(7):307–314
Amin M, Naseer A (1987) Synergic control in MIG welding 2—power current controllers for steady DC open arc operation. Met Constr, June 331–340
Zhu et al (1997) Theoretical prediction of the start-up phase in GMA welding. Weld J 76(7):229–234
Amin M (1981) Synergic pulse MIG welding. Met Constr, June 349–353
Montgomery DC (1991) Design and analysis of experiments, 3rd edn. Wiley, New York
Ferraresi VA, Figueiredo KM, Hiap O (2003) Metal transfer in the aluminum gas metal arc welding. J Braz Soc Mech Sci Eng XXV(3):229–234
Palani PK, Murugan N (2006) Selection of parameters of pulsed current gas metal arc welding. J Mater Process Technol 172:1–10
Palani PK, Murugan N (2006) Metal transfer and burn off characteristics of pulsed current gas metal arc welding: a review. Int J Joining Mater (in press)
Lambert JA (1989) Assessment of the pulsed GMA technique for tube attachment welding. Weld J 68(2):35–43
Amin M, Naseer A (1987) Synergic control in MIG welding 1—parametric relationships for steady DC open arc operation. Met Constr, January 331–340
Allum CJ, Quintino L (1985) Control of fusion characteristics in pulsed current MIG welding. Met Constr, April 242R–245R
Needham JC, Carter AW (1965) Material transfer characteristics with pulsed current. Br Weld J 5:229–241
Subramaniam et al (1998) Droplet transfer in pulsed gas metal arc welding of aluminum. Weld J 77(11):458–463
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Palani, P.K., Murugan, N. Modeling and simulation of wire feed rate for steady current and pulsed current gas metal arc welding using 317L flux cored wire. Int J Adv Manuf Technol 34, 1111–1119 (2007). https://doi.org/10.1007/s00170-006-0678-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-006-0678-0