A novel variable polarity welding power based on high-frequency pulse modulation

A new type of variable polarity welding power modulated with high-frequency pulse current is developed. Series of high-frequency pulse current is superimposed on direct-current-electrode-negative （DCEN）, which can improve the crystallization process in the weld bead as a result of the electromagnetic force generated by pulse current. Digital signal processor （DSP） is used to realize the closed-loop control of the first inverter, variable polarity output of the second inverter and high-frequency pulse current superposition.

Cathodic cleaning in variable polarity plasma arc welding of aluminum alloys

Variable polarity plasma arc welding (VPPAW) is one of the most excellent processes used for welding aluminum alloys recently. It combines the advantages of variable polarity welding and plasma arc welding, and can achieve the most rational heat distribution and cathodic cleaning. With the VPPAW equipment developed by authors, the cathodic cleaning regularity that is one of the most important problems in VPPAW is investigated in this paper. The results will be helpful in realizing the real cleaning mechanism.

Approximate entropy analysis of arc stability in VPPA-GMAW hybrid welding

Variable polarity plasma arc-gas metal arc welding(VPPA-GMAW)integrates the advantages of VPPA and GMAW,and it is particularly applied to weld thick-plates aluminum alloys.High-speed camera and data acquisition system were used to analyze the arc shape and the welding process electrical signal.According to the analysis of arc swing amplitude and the approximate entropy of arc voltage signal denoised by wavelet threshold method,the influence of VPPA frequency on the arc stability was studied.The results show that the approximate entropy of GMAW arc voltage decreases with the increase of VPPA frequency in a certain range,and the stability of the hybrid arc is significantly improved.The spectral analysis shows that the arc stability is reduced due to the resonance effect between the VPPA and the GMAW arc when the VPPA frequency closes to the GMAW arc pulse frequency.The results are helpful to understand hybrid welding mechanism and the selection of welding process parameters.

Optimization of HPVP-GTAW aluminum alloy process parameters for Al-Mg welded joints

Optimization of hybrid ultrahigh frequency pulse variable polarity gas tungsten arc welding （HPVP-GTAW） process was carried out to obtain the optimum weld characteristics of 5AO6-HX4 aluminum-magnesium alloy sheets of 3 mm thickness. The square butt joints were produced by HPVP-GTA W process, the microstructure and mechanical properties were systematically investigated. It is observed that the process parameters influence the weld microstructure and mechanical properties significantly. Weld microstructure is mainly composed of grid a （A1） solid solution, with a large number of intermetallic （ Mg2Al3 ） precipitates distributed in the matrix. The amount of ~ （ Mg2Al3 ） precipitates has an obvious difference with different parameters. Compared with that of the base material, tensile strength of 5AO6-HX4 alloy welded joints has a certain reduction, as well as the elongation and reduction of area. The optimized welding process parameters for 5A06-HX4 alloy sheets are presented.

Effect of pulse frequency on hardness characteristics of Al-Cu alloy HPVP-GTAW joints

AA 2219-0 Al-Cu alloy single bead welds were obtained by hybrid ultrahigh frequency pulse variable polarity gas tungsten arc welding （HPVP-GTAW） process with pulse frequency varying from 25 kHz to 70 kHz. Weld hardness characteristics which mainly depicted by microhardness and its gradient were investigated systematically. The results show that pulse frequency has a great effect on the hardness characteristics. The weld zone microhardness and its gradient with different pulse frequency present an evident fluctuant trend. The fluctuation of gradient is slight, illustrating that the mierostructure is uniform with pulse frequcncy varied from 35 kHz to 60 kHz. The fusion zone microhardness and its gradient foUow the similar trends but fluetuate greatly. Maximum value of gradient appears around the fusion boundary due to the coarse and non- uniform microstrueture. The maximum gradient at 60 kHz is only 25.5 % of that at 45 kHz. According to the study, the best hardness characteristics are achieved at 60 kHz frequency.