Analysis of Aluminum Alloy Double-Pulse MIG Welding Arc Signal Characteristics Based on Broadband Mode Decomposition

Welding voltage and current in arc signals are directly related to arc stability and welding quality.Process experiments with different parameters were organized according to the orthogonal experimental design method by constructing an aluminum alloy double-pulse metal inert gas(MIG)welding arc electric signal test platform.The data acquisition system of the aluminum alloy MIG welding process was established to obtain real-time arc signal information reflecting the welding process.The aluminum alloy’s collected double-pulse arc current signals are decomposed adaptively by broadband mode decomposition(BMD).The direct current(DC)signal,pulse signal,distortion signal,ripple signal,and noise signal are separated and extracted,and the composite multiscale fuzzy entropy(CMFE)is calculated for the component set of the electrical signal.The experimental results show that the current waveform obtained by the double-pulse MIG welding current signal is consistent with the corresponding weld forming diagram.Simultaneously,the composite multiscale fuzzy entropy is calculated for the arc characteristic parameters.The rationality of matching process parameters and arc stability of aluminum alloy’s double-pulse MIG welding were evaluated.

Effect of welding current on morphology and microstructure of Al alloy T-joint in double-pulsed MIG welding

The effect of current on the morphology of Al alloy T-joint in double-pulsed metal inert gas（DP-MIG） welding process was investigated by simulation and experiment.A three-dimensional finite element model and the DP-MIG heat source of double-ellipsoidal volumetric model were developed to simulate the temperature and stress fields under different welding conditions.The macro-morphology and microstructure of welding joints at the corresponding currents were observed in the experiment.The results show that the best condition is at an average current of 90 A and current difference of 40 A,when the maximum temperature is 200 °C higher than the fusion points,with the temperature difference of about 100 °C and stress change of 10 MPa between thermal pulse and thermal base.Under these conditions,Al alloy T-joint with proper fusion condition has smooth fish-scale welding appearance and finer microstructure.Furthermore,the thermal curves and stress distribution in the experiment are consistent with those in the simulation,verifying the precision of the welding simulation.

An initial study on welding procedure using tandem MIG welding of high strength aluminum alloy

The high-speed camera system and data acquisition system of welding parameters were created in tandem MIG welding of high strength aluminum alloy. The experiments were carried out in order to obtain the photos of droplet transfer under different welding parameters in pulsed mode. The droplet transfer mode of “one pulse one droplet” becomes the preferred selection during welding process because of its stable procedure and sound weld form. The parameter ranges for corresponding transfer mode were experimentally achieved, among which the stable droplet transfer mode of “one pulse one droplet” can be realized. These efforts brave the way for control weld heat input and weld formation in the future.

Droplet transition for plasma-MIG welding on aluminium alloys

The synchronous acquisition system of droplet image inspection and arc electric signals were established and the droplet transition characteristics of aluminum alloys were researched in the plasma-MIG welding process.Typical droplet transition modes include globular transfer mode,short circuiting transfer mode,metastable spray transfer mode and projected transfer mode.The result indicates that MIG droplet transfer frequency and droplet transfer modes are changed by introducing the plasma arc in the plasma-MIG welding process compared with the MIG welding on the aluminum alloys,which broadens the range of welding parameters when the stable welding process proceeds.The metastable spray transfer and projected transfer mode are proved to be the most optimal modes by comparing the stability of electronic signal,droplet transition,weld appearance and weld penetration.

Research on sinusoid modulated pulse MIG welding methodology

This article proposed a new methodology and the principle of sinusoid modulated pulse MIG welding, and systematically established the universal mathematical model of computation of the parameters of the sinusoid modulation pulse, achieving that the welding energy input can be effectively controlled and precisely regulated, the transition of pulse change is smooth and the welding process is stable and reliable. With the characteristics of sinusoidal waveform, such as infinite derivative continuity, eternal periodicity and limited control parameters, this article established the theoretical foundation for choiceness, unification and optimization of the parameters during the new sinusoid modulated pulse MIG welding. Bead-on-plate overlay welding is carried out on the pure aluminum sheet test sample for the test. The result indicated that during the welding process, the real-time current waveform is stable and clear; both the corresponding voltage and the instant welding energy waveform are very stable; the repeatability of the U-I graph plotted is high; its family of lines is clear, neat, and its distribution is concentrated showing that the welding process is stable and the neat and high quality ripple weld seam may be produced.

Grain refinement and improved properties through electromagnetic stirring in Al alloy MIG welds

This paper described the effects of external excitatory parameters of current and frequency on the microstructure and mechanical properties of weld metal in MIG welding with longitudinal electromagnetic field. With a high speed video camera capturing the images of arc shape, the mechanism of arc rotation and how the periodic contraction and expansion of arc affected the movement of molten pool were investigated. The technique resulted in fine equiaxed grains in weld metal and optimum parameters of electromagnetic stirring were suggested based on the extent of refinement. Fine-grained weld metal exhibited better yield strength and significant improvement in elongation.

Intelligent process expert database of double pulse MIG welding of AI-Si alloy

Based on double pulse welding process characteristics, expert database structure and work flow are designed. Further, multiple outstanding specifications of 1.0 ram-diameter wire are obtained through a large number of experiments. By making non-linear regression analysis on these groups of standards, the relationship between average welding current and other pulse parameters can be found out. Polynomial regression equation is set up for further realization of＂ parameter estimation function of the expert database. Finally, the preliminary developed expert database is tested. The result indicates that the unified adjusting and parameters estimation of the expert database leads to stable welding process and good weld appearance.

Weld pool image sensor for pulsed MIG welding

Visual image sensor is developed to detect the weld pool images in pulsed MIG welding. An exposure controller, which is composed of the modules of the voltage transforming, the exposure parameters presetting, the complex programmable logic device （CPLD） based logic controlling, exposure signal processing, the arc state detecting, the mechanical iris driving and so on, is designed at first. Then, a visual image sensor consists of an ordinary CCD camera, optical system and exposure controller is established. The exposure synchronic control logic is described with very-high-speed integrated circuit hardware description language （VHDL） and programmed with CPLD , to detect weld pool images at the stage of base current in pulsed MIG welding. Finally, both bead on plate welding and V groove filled welding are carried out, clear and consistent weld pool images are acquired.

Analysis of droplet transfer of pulsed MIG welding based on electrical signal and high-speed photography

In order to study how welding parameters affect welding quality and droplet transfer, a synchronous acquisition and analysis system is established to acquire and analyze electrical signal and instantaneous images of droplet transfer simultaneously, which is based on a self-developed soft-switching inverter. On the one hand, welding current and voltage signals are acquired and analyzed by a self-developed dynamic wavelet analyzer. On the other hand, images are filtered and optimized after they are captured by high-speed camera. The results show that instantaneous waveforms and statistical data of electrical signal contribute to make an overall assessment of welding quality, and that optimized high-speed images allow a visual and clear observation of droplet transfer process. The analysis of both waveforms and images leads to a further research on droplet transfer mechanism and provides a basis for precise control of droplet transfer.

Modelling of the plasma-MIG welding temperature field

A three-dimensional simulation model for the plasma-MIG welding process, which takes the interaction between the plasma arc and MIG arc into account, is presented and the quasi-steady temperature fields on the workpiece are calculated with the model. The 10 mm-5A06 aluminum alloy is welded and the temperature fields are measured with the thermoelectric couple. The simulation results and measured results show that the biggest deviation of peak temperature between them is below 20 ℃, which indicates good coincidence between the simulation and measurement.

SENSORING DROPLET SPRAY TRANSFER IN MIG WELDING BASED ON ARC SPECTRUM SIGNAL

The method to detect droplet transfer by means of arc spectrum, while the experiment sets, testing principle and data processing procedure,are presented. The experiment and analysis results show that arc spectrum signal can be utilized to detect and measure the transfer procedure, the transfer modes and the transfer parameters. The arc spectrum signal enjoys excellent quality with high signal amplitude. Each transfer mode has its specific typical signal mode, and the pulse outline corresponds to an integrated transferring procedure of one droplet. All these features of arc spectrum signal can be easily applied hi the control of transfer procedure,the identification and stabilization of transfer mode and the measurement of transfer parameters.

Noise wavelet-suppressing on electric signals in meso-spray process of pulse MIG welding of aluminum

An analysis with Fourier series on electric signals of meso-spray process of pulse MIG welding of aluminum shows many harmonic waves of different frequency in the signals, including the inherent high, low frequency elementary waves of short circuit and the harmonic waves from pulse current besides the noise signals of high frequency. The wavelet filtering with adjustable threshold is applied to study and handle the electric signals from meso-spray process of pulse MIG welding of aluminum, displaying a good solution on suppressing the noise in the signals.

Digital control system for pulsed MIG welding power based on STM32

Digital control system for pulsed MIG welding power based on STM32 is set up with 32-bit STM32FlO3ZET6 directing against the pulse waveform modulation of pulsed MIG welding. High-frequency inverter and medium-low frequency pulse waveform modulation of pulsed MIG welding are realized by using the integrated PWM module within STM32 to generate PWM signals of phase-shifted full-bridge soft-switching and constant-current control of output current is achieved by means of anti-windup PI control algorithm to improve the stability and reliability of control system. Experimental results demonstrate that the designed digital control system based on STM32 can achieve pegrect pulsed MIG welding technique with stable welding process and good weld appearance, fully demonstrating the advantages of digital control based on STM32.

Correction factor based double model fuzzy logic control strategy of arc voltage in pulsed MIG welding

According to the feature of arc voltage control in welding steel using pulsed MIG welding, a correction factor based double model fuzzy logic controller (FLC) was developed to realize the arc voltage control by means of arc voltage feedback. When the error of peak arc voltage was great, a coarse adjusting fuzzy logic control rules with correction factor was designed, in the controller, the peak arc voltage was controlled by the wire feeding speed by means of arc voltage feedback. When the error of peak arc voltage was small, a fine adjusting fuzzy logic control rules with correction factor was designed, in this controller, the peak arc voltage was controlled by the background time by means of arc voltage feedback. The FLC was realized in a Look-Up Table (LUT) method. Experiments had been carried out aiming at implementing the control strategy to control the arc length change in welding process. Experimental results show that the controller proposed enables the consistency of arc length and the stability of arc voltage and welding process to be achieved in pulsed MIG welding process.

Influences of acoustic field parameters on welding arc behavior in ultrasonic-MIG welding

By applying ultrasonic-MIG welding as research object, the behaviors of welding arc were analyzed with varied ultrasonic parameters in welding using arc images recorded by high-speed camera. The influences of the current by exciting ultrasonic and the height and shape of ultrasonic radiator on welding arc were studied. Results showed that when the current was 150 mA, ultrasonic showed most distinct compressive effect on arc. The compressive volumes of arc length at different heights were calculated by adjusting the height of ultrasonic radiator continuously from 10 mm to 35 mm, there were three maximum points. The compressive degrees of them reduced successively. By utilizing different shapes of ultrasonic radiator, it revealed that ultrasonic radiator with spherical crown surface showed better compressive effect in a larger welding standard scope. When radius of radiator increased, axial compressive volume of arc enlarged, while an increasing curvature radius led to mare distinct radial compression of arc.

Study on Evaluation Method of Aluminum alloy Pulse MIG Welding Stability Based on Arc Voltage Probability Density

Bring forward a new analytical method in order to evaluate the stability of the process of aluminum alloy pulsed MIG welding. The ratio of the first and the second peak in arc voltage signal probability density was selected to evaluate aluminum alloy pulse MIG welding stability. By calculating the arc voltage signal probability density from 80 sets of welding experiments, the ratio of the two peaks in arc voltage probability in every set was captured. And the evaluation system of aluminum alloy pulse MIG welding stability was established. The smaller the ratio of peaks in arc voltage signal probability density is, the better the stability of the welding will be;the bigger the ratio of peaks in arc voltage signal probability density is, the poorer the stability of the welding will be.

Self-adjusting dynamic characteristics of pulsed MIG welding for aluminum alloys

Pulsed MIG welding is suitable for aluminum alloys welding, because spray transfer and excellent profile can be arrived during whole welding current range, and the energy of droplet can be controlled to overcome losing of alloy elements with lower melting and steam point by controlling pulse current and pulse time. Because of the special physic properties of aluminum alloys, there are different requirements for pulsed MIG welding between starting arc short circuit and drop transfer short circuit, pulse period and base period. In order to satisfy the need of aluminum alloys MIG welding, self adjusting dynamic characteristics are designed to output different dynamic characteristics in different welding startes. The self adjusting dynamic characteristics of pulsed MIG welding are achieved through a short circuit controller and a dynamic electronic inductor. The welding machine(AL MIG 350) with self adjusting dynamic characteristics has a high rate of successfully starting arc up to 96%, and the short circuit time during transfer is less than 1 ms, in the mean time, the arc is stiffness, spatter is low and weld appearance is good.

Microstructure and Corrosion Properties of the Plasma-MIG Welded AA5754 Automotive Alloy

The influence of heating cycles during plasma metal inert gas (MIG) welding on the microstructure and corrosion properties of the AA5754 automotive alloy has been investigated. The high heat input during plasma-MIG welding results in a significant modification in the microstructure of the AA5754 alloy adjacent to the fusion boundaries. As a consequence of partial melting of the Al-Fe-Mn-(Si) intermetallics at the partially melted zone (PMZ) and segregation of the high melting point elements (particularly Fe and Mn) toward the fusion zone, severe galvanic corrosion attacks can be enhanced along the PMZ of the AA5754 weld during exposure to aqueous corrosion environments.

局部干法水下快频脉冲MIG焊电源研制

针对复杂水下环境焊接过程对焊接电源超高动特性与精确控制需求,设计基于SiC模块的快频脉冲焊接电源功率主电路,开发全数字化控制系统,研制出局部干法水下快频脉冲MIG焊电源(local dry underwater fastfrequency pulsed MIG,LDU-FFPMIG).研制的LDU-FFPMIG焊接电源额定输出电流为400 A,能精确输出多种0~30 kHz的快频脉冲电流波形,快频脉冲电流幅值高达200 A.提出LDU-FFPMIG焊接新工艺,将快频脉冲应用到304不锈钢局部干法水下MIG焊接,探究快频脉冲对传统局部干法水下脉冲MIG焊的影响.结果表明,研制的LDU-FFPMIG焊接电源能够实现稳定的局部干法水下MIG焊,可获得良好的焊缝成形;快频脉冲电流的引入可显著提高电弧能量密度和焊接稳定性,减小熔宽(B)、增大熔深(H),焊缝成形系数(B/H)减小约30%,并且可以细化晶粒.

Effect of V content on microstructures and properties of TiC cermet fusion welding interface

The effects of vanadium(V)on the microstructures and mechanical properties of the TiC cermet fusion welding interface were studied by adjusting the content of V in the self-developed flux-cored wires using metal inert gas arc(MIG)welding for surfacing on the TiC cermet.The results show that the increase in V content promotes the element diffusion between TiC cermet and weld metal.There are no de-fects observed in the interface,and the diffusion of elements refers to excellent metallurgical bonding.The shear strength of the fusion zone initially decreases and then increases with the increase in V content.The maximum shear strength of the TiC cermet/weld interface,reaching 552 MPa,occurred when the V content reached 0.65%.Meanwhile,the average hardness in the transition zone reached 488.2 HV0.2.