INP

Leibniz Institute for Plasma Science and Technology
Felix-Hausdorff-Str. 2
17489 Greifswald
GERMANY

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The Leibniz Institute for Plasma Science and Technology (INP) is the largest non-university institute in the field of low temperature plasmas, their basics and technical applications in Europe. The institute carries out research and development from idea to prototype. The topics focus on the needs of the market. At present, plasmas for materials and energy as well as for environment and health are the focus of interest.

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A simplified voltage model in GMAW

Thermal Plasma Technology

The relation between the voltage and the arc length in gas metal arc welding (GMAW) is an important characteristic. It depends on a complex distribution of the electric conductivity along the current path and does not depend on the arc length only. Based on electric measurements and the arc length determination from high-speed arc images, a simplified electrical model is introduced for a pulsed GMAW process. It shows the relation of voltage, current, arc length and free wire length and considers also their temporal evolution during the process in particular during the high-current phase. Previous detailed studies of the sheath voltage and the resistances in the contact tube, the free wire, the droplet depot and the arc in pulsed processes with changing arc lengths have been used. The electrical model shows a sufficient agreement with measurements also for parameter ranges of the wire feed speed and the contact-to-workpiece-distance (CTWD) which have not been considered in the model deduction. This data set includes the model parameters, examples of arc images, measurements of voltage, current and arc length as well as model predictions for voltage and arc length in comparison with the measurements.

GMAW
high-current arc
FieldValue
Group
INP
ISF RWTH Aachen
Authors
Zhang, Guokai
Gött, Gregor
Uhrlandt, Dirk
Lozano, Philipp
Sharma, Rahul
Release Date
2020-03-20
Identifier
cdb022d4-7260-459a-9bce-59a7d011deac
Permanent Identifier (DOI)
10.34711/inptdat.146
Permanent Identifier (URI)
https://www.inptdat.de/node/146
Is supplementing
G. Zhang et al., Weld. World 64 (2020) 1625
Plasma Source Name
Miller Auto-Axcess™ 450
Plasma Source Application
gas metal arc welding
Plasma Source Specification
pulsed
DC
low frequency
atmospheric pressure
thermal
Plasma Source Properties

Welding parameters: pulsed process in DC-mode, one-drop-per-pulse process, wire 1.2 mm in diameter, wire feed speed 3 to 6 m/min, welding speed 30 cm/min, contact tip setback 3 mm, contact-to-workpiece-distance (CTWD) 9 to 21 mm, peak current (I) 300 to 650 A, base current 25 A, pulse frequency 50 to 130 Hz, pulse duration 1 to 1.5 ms
Plasma Medium Name
Ar
CO2
Plasma Medium Properties

Shielding gas Ar+2.5%CO2, gas flow rate 15 l/min, atmospheric pressure
Plasma Target Name
mild steel
Plasma Target Properties
Mild steel: wire material G3Si1, base material S235
Plasma Target Procedure
Bead-on-plate welding
Plasma Diagnostics Name
current measurement
voltage measurement
high-speed imaging
Plasma Diagnostics Properties

Welding current and total voltage measurement by a current probe (Tektronix TCP404XL) and a differential probe (Tektronix TDP0500) and recorded by an oscilloscope (Tektronix DPO4104).

Arc and wire image recording with a monochrome high-speed camera MotionPro Y4, frame rate of 6000 fps, exposure time of 16 µm, parallel to the workpiece and in welding direction, synchronous recording through two different narrow-band spectral filters with the central wavelengths of 437nm and 811nm to image the radiation of the metal vapour and those of the argon shielding gas.
Plasma Diagnostics Procedure

The total voltage was measured between the contact tube of the welding torch, where a specific junction has been mounted, and the workpiece.

An image processing via Matlab has been used to treat arc images recorded with the two different filters, to reconstruct the metal vapour range and the shielding gas range of the arc and to estimate the arc column length.
Language
English
License
Creative Commons Attribution 4.0 International (CC BY 4.0)
Public Access Level
Public
Contact Name
Uhrlandt, Dirk
Contact Email
uhrlandt@inp-greifswald.de

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