Role of material properties on metal transfer dynamics in gas metal arc welding

In the gas metal arc welding (GMAW) process, metal transfer dynamics, influenced by wire material properties such as electrical conductivity and surface tension, serve as key sources of mass and heat for metal deposition on substrates. To elucidate the role of these material properties on metal transfer dynamics from a driving force perspective, this study examined molten droplet elongation across five distinct wires: Al, Cu, Fe, Ni, and Ti. Additionally, a unique non-transferred arc welding setup equipped with a consumable wire anode and two tungsten cathodes was introduced, allowing for observations at minimized arc lengths and preventing current concentration in molten droplets. For Al and Cu wires, while only projected-spray transfer was observed under sufficient arc length conditions, a shift to minimized arc length resulted in significant droplet elongation and a transition to streaming-spray transfer. This contrast emphasized the impact of high electrical conductivity in reducing the internal gradient of electromagnetic pressure and inhibiting the occurrence of streaming-spray transfer. Further substantiating this mechanism, Fe, Ni, and Ti wires revealed that higher electrical conductivity corresponded to an increased transition current to streaming-spray transfer. Additionally, surface tension played a crucial role in the formation of molten droplets and ensured transfer stability, with its influence varying at different current levels. These insights contribute to our comprehensive understanding of arc plasma and molten metal interactions. Our study proposes material-specific strategies to optimize metal transfer dynamics, leading to enhanced control over weld bead formation and overall mechanical properties of welded joints in the GMAW.