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Title: Sensing of metal-transfer mode for process control of GMAW (gas metal arc welding)

Abstract

One of the requirements of a sensing system for feedback control of gas metal arc welding (GMAW) is the capability to determine the metal-transfer mode. Because the operating boundary for the desired transfer mode, expressed as a function of mass input and heat input, may vary due to conditions beyond the control of the system, a means of detecting the transfer mode during welding is necessary. A series of sensing experiments was performed during which the ultrasonic emissions, audio emissions, welding current fluctuations and welding voltage fluctuations were recorded as a function of the transfer mode. In addition, high speed movies (5000 frames/s) of the droplet formation and detachment were taken synchronously with the sensing data. An LED mounted in the camera was used to mark the film at the beginning and end of the data acquisition period. A second LED was pulsed at a 1 kHz rate and the pulses recorded on film and with the sensor data. Thus events recorded on the film can be correlated with the sensor data. Data acquired during globular transfer, spray transfer, and stiff spray or streaming transfer were observed to correlate with droplet detachment and arc shorting. The audio, current, and voltagemore » data can be used to discriminate among these different transfer modes. However, the current and voltage data are also dependent on the characteristic of the welding power supply. 5 refs., 3 figs., 1 tab.« less

Authors:
; ;
Publication Date:
Research Org.:
EG and G Idaho, Inc., Idaho Falls, ID (USA)
Sponsoring Org.:
DOE/ER
OSTI Identifier:
7140450
Report Number(s):
EGG-M-89148; CONF-890770-9
ON: DE90010946
DOE Contract Number:  
AC07-76ID01570
Resource Type:
Conference
Resource Relation:
Conference: 16. annual review of progress in quantitative nondestructive evaluation, Brunswick, ME (USA), 23-28 Jul 1989
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; 99 GENERAL AND MISCELLANEOUS//MATHEMATICS, COMPUTING, AND INFORMATION SCIENCE; GAS METAL-ARC WELDING; PROCESS CONTROL; COMPUTERIZED CONTROL SYSTEMS; DATA ACQUISITION SYSTEMS; DROPLETS; FEEDBACK; POWER SUPPLIES; ARC WELDING; CONTROL; CONTROL SYSTEMS; ELECTRONIC EQUIPMENT; EQUIPMENT; FABRICATION; JOINING; PARTICLES; WELDING; 420200* - Engineering- Facilities, Equipment, & Techniques; 990200 - Mathematics & Computers

Citation Formats

Carlson, N M, Johnson, J A, and Smartt, H B. Sensing of metal-transfer mode for process control of GMAW (gas metal arc welding). United States: N. p., 1989. Web.
Carlson, N M, Johnson, J A, & Smartt, H B. Sensing of metal-transfer mode for process control of GMAW (gas metal arc welding). United States.
Carlson, N M, Johnson, J A, and Smartt, H B. Sun . "Sensing of metal-transfer mode for process control of GMAW (gas metal arc welding)". United States.
@article{osti_7140450,
title = {Sensing of metal-transfer mode for process control of GMAW (gas metal arc welding)},
author = {Carlson, N M and Johnson, J A and Smartt, H B},
abstractNote = {One of the requirements of a sensing system for feedback control of gas metal arc welding (GMAW) is the capability to determine the metal-transfer mode. Because the operating boundary for the desired transfer mode, expressed as a function of mass input and heat input, may vary due to conditions beyond the control of the system, a means of detecting the transfer mode during welding is necessary. A series of sensing experiments was performed during which the ultrasonic emissions, audio emissions, welding current fluctuations and welding voltage fluctuations were recorded as a function of the transfer mode. In addition, high speed movies (5000 frames/s) of the droplet formation and detachment were taken synchronously with the sensing data. An LED mounted in the camera was used to mark the film at the beginning and end of the data acquisition period. A second LED was pulsed at a 1 kHz rate and the pulses recorded on film and with the sensor data. Thus events recorded on the film can be correlated with the sensor data. Data acquired during globular transfer, spray transfer, and stiff spray or streaming transfer were observed to correlate with droplet detachment and arc shorting. The audio, current, and voltage data can be used to discriminate among these different transfer modes. However, the current and voltage data are also dependent on the characteristic of the welding power supply. 5 refs., 3 figs., 1 tab.},
doi = {},
url = {https://www.osti.gov/biblio/7140450}, journal = {},
number = ,
volume = ,
place = {United States},
year = {1989},
month = {1}
}

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