Advanced gas metal arc welding processes

There is an increased requirement in the automotive, food and medical equipment industries to weld heat-sensitive materials, such as thin sheets, coated thin plates, stainless steel, aluminium and mixed joints. Nevertheless, relevant innovations in arc welding are not widely known and seldom used to their maximum potential. In the area of gas metal arc welding welding processes, digitalisation has allowed integration of software into the power source, wire feeder and gas regulation. This paper reviews developments in the arc welding process, particularly the effect of the set-up of the welding process parameters on waveform deposition. It is found that good weldability, good mechanical joint properties and acceptable process efficiency can be obtained for thin sheets through advanced power source regulation, especially over short circuiting, controlled polarity and electrode wire motion. The findings presented in this paper are valuable for waveform and deposition prediction. The need is furthermore noted for an algorithm that integrates gas flow parameters and wire motion control, as well as a variable sensor on the tip of the electrode, permitting flexibility of control of the current and the voltage waveform.