Electromagnetic Characteristic of Twin-wire Indirect Arc Welding

Traditional welding methods are limited in low heat input to workpiece and high welding wire melting rate. Twin-wire indirect arc（TWIA） welding is a new welding method characterized by high melting rate and low heat input. This method uses two wires one connected to the negative electrode and another to the positive electrode of a direct-current（DC） power source. The workpiece is an independent, non-connected unit. A three dimensional finite element model of TWIA is devised. Electric and magnetic fields are calculated and their influence upon TWIA behavior and the welding process is discussed. The results show that with a 100 A welding current, the maximum temperature reached is 17 758 K, arc voltage is 14.646 V while maximum current density was 61 A/mm2 with a maximum Lorene force of 84.5 ~tN. The above mentioned arc parameters near the cathode and anode regions are far higher than those in the arc column region. The Lorene force is the key reason for plasma velocity direction deviated and charged particles flowed in the channel formed by the cathode, anode and upper part of arc column regions. This led to most of the energy being supplied to the polar and upper part of arc column regions. The interaction between electric and magnetic fields is a major determinant in shaping TWIA as well as heat input on the workpiece. This is a first study of electromagnetic characteristics and their influences in the TWIA welding process, and it is significant in both a theoretical and practical sense.

Microstructure and mechanical properties of twin-wire arc spraying Ni-Swt.% AI coating on 6061-T6 aluminum alloy

Thermal sprayed Ni-5wt.% Al coating was fabricated on the substrate of 6061-T6 aluminum alloy by twin-wire arc spraying. Experimental results indicated that the average value of bond strength was around 46. 90 MPa, the average hardness was 240 HV and the average value of surface roughness was about O. 14 mm. Friction and wear test results showed that the dry friction coefficient of Ni-5wt.% Al coating firstly decreased, and then tended to a slight increase after 200 cycles. In the early abrasion stage, adhesion wear played the key role for wear mechanics of Ni-5wt.% Al coating, but gradually abrasive wear became to replace adhesion wear.

Twin-wire Submerged Arc Welding Process of a High-strength Low-alloy Steel

The measurement of thermal cycle curves of a high-strength low-alloy steel （HSLA） subjected twin-wire submerged arc welding （SAW） was introduced. The thermal simulation test was performed by using the obtained curves. The impact toughness at -50 ℃ temperature of the simulated samples was also tested. OM, SEM and TEM of the heat-affected zone （HAZ） of some simulation specimens were investigated. The results showed that the HSLA endured the twin-wire welding thermal cycle, generally, the low-temperature toughness values of each part of HAZ was lower than that of the parent materials, and the microstructure of coarse-grained zone（CGHAZ） mainly made up of granular bainite is the reason of the toughness serious deterioration. Coarse grain, grain boundary carbide extract and M-A island with large size and irregular polygon, along the grain boundary distribution, are the reasons for the toughness deterioration of CGHAZ. The research also showed that selected parameters of twin-wire SAW can meet the requirements to weld the test steel.

Study on twin-wire pulsed MIG welding power supply based on DSP and CAN

A design proposal for twin-wire pulsed MIG welding power supply based on DSP （ digital signal processor） and CAN （ controller area network ） is put forward. By ase of the CAN bus, the synergic control between the master and slave power supplies can be realized. And in this way, their peak currents can be guaranteed to be alternative and the interference between the two arcs can be decreased efficiently. The hardware design, software design and relative tests are provided in this paper. Tests show that the power supply can meet the design requirements of twin-wire welding.

Arc characteristics of twin-wire indirect arc gas shielded welding

Twin-wire indirect arc gas shielded welding is a novel welding method. By recording the arc shape and welding parameters, the effects of welding parameters and included angle on arc characteristics are discussed in this paper. The experimental results show increasing welding current can prompt centralized and straight of arc due to increasing plasma force and electric magnetic pinch effect. Increasing arc voltage can increase the size and brightness of the arc, as a result of increasing arc energy. The reducing of included angle increases the electric magnetic pinch effect, the arc becomes slender and supplies higher energy. It is thought the smaller included angle is beneficial to obtain perfect weld bead.

Inverter power supply system for high-power twin-wire pulsed GMAW

A type of novel inverter power supply system for high-power twin-wire pulsed gas metal arc welding （GMAW） is presented mainly for dealing with the disadvantages of the conventional power supply for twin-wire pulsed GMA W of which the output power is generally difficult to increase due to limitations of the power of semiconductors and the power density of magnetic devices. In the power supplies for the master and slave arcs, the digital signal processor （DSP） TMS320F28335 is used to form the DSP- based synergic control system for parallel high-power pulsed GMA W, which achieves high-power output of two parallel inverters controlled by a single DSP ; master-slave communication is achieved by using e controller area network （eCAN）module of DSP, thas realizing anti-phase pulse output of high-power twin-wire pulsed GMA W and reducing the interference between twin arcs. The experiment results demonstrate that the designed inverter power supply system for high-power twin-wire pulsed GMAW can bring about high-power efficiency of welding, stable welding process and proper formation of welds.

Twin-wire SAW welding of 70 kg class high strength steel

The twin-wire SAW welding process was investigated using Baosteel 70 kg class high strength steel, and the properties of the joints were studied using conventional single and double-faced grooves as well as an optimized groove. The results showed that by using an optimized double-faced groove, a small root face, and no back gouging, a small welding heat input was achieved and thus the joint strength and toughness were improved significantly. Also, removing back gouging reduced the labor required in the process. The weld reinforcement and deformation were observed to be rather small.

Research and engineering application of the arc welding pulsed controller technology

The tenacity of heat-affected zone （HAZ） will decline and the size of grains will increase, because of the overheating on HAZ when submerged are welding （SAW） is ased to thick plate with high heat input. The shaping will worsen when SAW is used to thin plate with high current at high speed. A new SAW technology, the pulsed direct current （DC） automatic SAW, will be put forward in this paper in order to overcome the above shortcomings. And a pulsed controller with micro-controller unit （MCU） as the core, nixie tube （NT） and keyboard as the man-machine conversation interface is developed. The main functions of the pulsed controller include the output of pulsed welding current and the working with twinwire. The research has widely prospects in application with significant meanings in theory and practical engineering.

Inclusion behavior and microstructure of weld metal with Ce in twin wire high heat input submerged-arc welding

In this study,the welding thermal cycle curve exhibited two temperature peaks in high heat-input twin-wire separate-pool submerged-arc welding and coarse-grained heat affected zone existed in the welded joint. The inclusions of primary weld metal and coarse-grained heat affected zone of Ce-added SAW should be Al_2O_3,MnO,SiO_2,TiO,Ce_2S_3,CeS,Ce_2O_2S and Ce_2O_3. Under the effect of welding thermal cycle,oxy-sulfides inclusions of Ce,the diameter of which was less than 2. 0 μm,slightly grew larger,but the composition and type of the inclusions didn't change. The microstructure of the large heat input weld metal had acicular ferrite that Ce oxide sulphide particles induced nucleation and proeutectoid ferrite. In the coarse-grained heat affected zone of weld metal,home-position precipitation of acicular ferrite and sympathetic acicular ferrite were both observed. It was supposed that previous crystal cells of acicular ferrite in austenite grain promoted home-position precipitation of acicular ferrite. Meanwhile,sympathetic acicular ferrite tended to nucleate at the primary acicular ferrite grain boundaries,where high dislocation density was located,and grew inside the neighboring carbon-depleted austenitic regions. The granular bainite nucleated in the austenitic zone with high carbon content close to acicular ferrite and sympathetic acicular ferrite.

Quasi-TEM mode propagation in twin-wire THz waveguides

We numerically investigate the trade-offs between the dispersion properties,coupling efficiency,and geometrical constraints in dual-wire （twin-lead） terahertz （THz） waveguides.In particular,we show that their inherent linearly polarized quasi-transverse electromagnetic （TEM） modes exist for waveguide transverse dimensions comparable with the wavelength,enabling significant end-fire coupling （10%） for numericalaperture limited Gaussian beams while supporting a relatively low-dispersion propagation of below 0.5 ps 2 /m,as desired for short-pulse time-domain spectroscopy applications.Starting from the dual-wire structure,we also demonstrate that low-dispersion tapers can be designed to improve coupling efficiency.

Microstructure characterization and mechanical properties of thermal sprayed Ni-20wt. % Al coating

Thermal sprayed Ni-20wt. % Al coating is fabricated on 6061-T6 aluminum alloy substrates by twin-wire arc spraying （TWAS）. Experimental results present that the average bonding strength is around 53 MPa and the average hardness reaches 325 HV. The Vickers microhardness of NiAl and Ni3Al intermetaUic compounds is larger than that of the substrate, which is beneficial for improving the wear property. Wear mechanism exhibits features of adhesive wear. Friction and wear test results indicate that the wet friction coefficient is higher than the coefficient of dry friction after 200 cycles, and variations of the wet friction coefficient are relatively smaller.

Microstructures and Properties of Copper-steel Welded Joint by Twin Wire Welding

The paper studies the twin wire butt welding of 6mm-thick T2 copper and Q235 steel plate by using the twin wire consisting of one copper-plated welding wire and one steel welding wire.According to the appearance detection,the weld joint gained is sound in shape without crackles,pores,incomplete fusion and other defects.As shown by the mechanical property,SEM and EDAX and in the metallographic analysis and test,the rupture position of copper-steel welded joint is located in the copper-part HAZ when the tensile strength reaches above 210MPa and Fe content of the welded joint involved in 1# test specimen reaches around 22.78%-26.75%,with the hardness achieving between 102～107HB and the weld structure being (α+ε) duplex solid solution.