The metal transfer behavior and the effect of arcing mode on metal transfer process in twin-arc integrated cold wire hybrid welding

In response to the demands of high-efficient welding, twin-arc integrated cold wire hybrid welding technology was proposed in this paper. In order to realize a stable welding process, the research was focused on the effect of welding electrical parameters on the metal transfer process of simultaneous arcing to find a proper range of process parameters. In addition, the experimental research found a new factor to affect the metal transfer mode, i.e., arcing mode, and its effect mechanism was discussed in greater detail. The results showed that both the leading wires kept simultaneous arcing with in-phase pulse currents supplied to two wires. The metal transfer modes were divided into two types: one is one droplet per pulse, and the other is one droplet multiple pulses, which highly depended on arc voltage. At first, the main metal transfer was one droplet multiple pulses at lower arc voltage. Then the metal transfer mode started to change to one droplet per pulse with the increase of arc voltage. Finally, when arc voltage continuously increased to a certain value, one droplet multiple pulses once again occurred. This was mainly because the great increase of arc length restricted the expansion of arc root. What is more important, through the comparison between the metal transfer processes of simultaneous arcing and alternative arcing, it was found that the arcing mode had a significant effect on the metal transfer mode, and the main reason was the arcing mode affected the electric field intensity of arc column.