Weld Appearance And Current Signal Analysis Of Rotating Arc Guided Tandem Co-pool Gas-shielded Metal Arc Welding

Industrial modernization market competition prompted the rapid development of advanced high efficiency welding technology methods, especially the development of the double wire serial efficient MIG welding remarkable achievements, however, double wire serial MAG/MIG welding arc has the very high welding speed, cannot adopt manual welding, therefore, high speed precision of seam tracking become double wire serial MAG/MIG welding of urgent need. In this article, we combine rotating arc sensor with tandem arc gas-shielded welding, designed a rotating arc guided tandem co-pool arc sensor process, it not only can achieve the deposition rate of tandem gas-shielded arc welding, but also has the seam tracking ability of rotating arc. At the same time using rotating arc on mixing effect in the molten pool of weld organization, decrease porosity, improve the weld strength and plasticity, in the implementation and improve the quality of welding seam tracking.Firstly, based on surfacing welding experiments of the rotating arc welding robots, we study the effects of welding parameter on weld appearance. The results show that as welding current increases, weld width, penetration, reinforcement and deposition rate increase but weld width become wider remarkably, while form factor reduces, reinforcement coefficient remains unchanged; To the wake of welding voltage increases, penetration, weld width and rotational frequency increase, whereas reinforcement decreases and deposition rate keeps unchanged, weld coefficient stays the same at first and decreases then; As rotational frequency increases, penetration and reinforcement reduce, form factor coefficient and reinforcement coefficient still increase, but the weld width firstly decreases and then increases; With the increase of welding speed, form factor and reinforcement coefficient increases slightly, while the others decrease and deposition rate decreases exponentially.Secondly, we designed a rotating arc guided tandem co-pool arc sensor, then we studied the effects of welding parameter on weld appearance of rotating arc guided tandem co-pool gas-shielded metal arc welding, and compared the weld appearance of rotating arc welding with tandem wire co-pool gas-shielded metal arc welding. We found that rotating arc guided tandem co-pool gas-shielded metal arc welding not only improve the efficiency in welding speed, but also improve the weld appearance remarkably. When the weld speed of TCR-GMAW achieved 90cm/min, it’s deposition rate can achieve to 7.83g/s, while the deposition rate just only 5.99g/s when the weld speed of rotating arc welding achieved 80cm/min.Finally, we did statistical analysis of weld current signal which collected from rotating arc guided tandem co-pool gas-shielded metal arc welding experiment, and found that: Compared with trailing wire, lead wire welding arc is more stability, and its welding current is volatile. Increasing the lead wire or trailing wire welding current will affect the stability of the two arc. Increased the lead wire welding voltage can improve the stability of the lead arc, but will make the following wire arc stability is lower; Increase following wire welding voltage, the influence of lead wire arc stability is not remarkably, but will weaken the stability of itself welding arc. Otherwise, we do the seam tracking experiment of TCR-GMAW, and filtering its current signal, we found it’s waveform have some same characteristic of sine waveform, this show that TCR-GMAW can rise to the purpose of the seam tracking.