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Adresa autora / Author's address: Institut za varilstvo (Welding Institute), Ptujska 19, 1000 Ljubljana, Slovenia
Izvod Abstract
U radu so prikazane raznolike metode procene The paper treats several methods of evaluating the
stabilnosti MIG/MAG zavarivanja. Stabilnost procesa stability of MIG/MAG welding processes. The
zavarivanja utjiče na zavarljivost i zavisi od stability of the welding process influences weldability
mnogobrojnih parametara. Najnepogodniji rezultati loše and is affected by numerous parameters. The most
stabilnosti luka su izštrcki, koji su problematični u smislu unfavourable results of poor arc stability are
gubitka materijala, produženje vremena izrade zbog spatters which are problematic in terms of material
dodatnog čiščenja, kao i zbog lošeg izgleda šava. losses, extension of production times due to
Metode, koje su opisivane u ovom radu baziraju na cleaning, as well as unaesthetic appearance. The
merenju ovisnosti jačine struje zavarivanja i napona methods described in the paper are based on
zavarivanja od vremena. Rezultati eksperimentalnog measurement of time-varying welding current and
rada baziraju na analizi stabilnosti električnog luka welding voltage. The results of the experimental
sprovedene kod zavarivanja u različitih zaštitnim part of the paper are based on stability analyses
atmosferama gasa. Takoñe su uporeñena dva različita carried out with different gas-shielding
režima zavarivanja. Ispitivana su zavarivanja sa kratkim atmospheres. Also two different welding regimes
lukom i sa prskajučim lukom. were compared. The first was short-circuit material
transfer, and the second spraying material transfer.
The stability of a welding process can be assessed by Figure 1: Dependence of welding current and voltage
the control and analysis of the results obtained with 600 120
measurements. The least complicated and most 500 110
frequently used method of analysis of the welding 400 100
I [A]
300 90
process stability is based on the measurement of the 200 80
dependence of welding current intensity and welding 100 70
U [V]
-300 30
-400 20
-500 10
3 EXPERIMENTAL PROCEDURE -600 0
0 20 40 60 80 100 120 140 160 180 200
t [ms]
The experiments were focused on measurements of
welding voltage and current in the MIG/MAG welding on time in short-circuit material transfer.
process. Welding was fully automated. Surfacing was
applied to a sheet with a quality of low-alloy structural 3.2 Probability distribution of short-circuit periods
steel. A synergic inverter power source and a suitable and arc burning
automated system for burner guidance were used. A In the short-circuit material transfer, the welding
filler material used was a 1.6 mm solid welding wire of process in the direction of the time axis may be
quality SG 2. Three types of the shielding atmosphere evaluated in the following manner. The short-circuit
were used in the experiments, i.e., pure CO2, a two- transfer welding process may be divided, along the time
component 82% Ar/18%CO2 gas mixture, and a four- axis, into two characteristic phases:
component T.I.M.E. (Transferred Ionized Molten • arc burning time,
Energy) gas mixture (65% Ar/26.5% He/8%CO2/0.5% • short-circuit period.
O2).
The above random variables may be statistically
The measuring part of the system consisted of a shunt, processed and presented in terms of probability
low-pass filters, analogue-to-digital and digital-to- distributions (see Figure 2).
analogue (A/D-D/A) converters, and a personal
computer. The sampling frequency of the measurement
chain was 6 kHz.
600 45
500 40
400
35
I [A]
300
200 30
100
p [%]
25
0
20
tO t KS 50
40 15
U [V]
30 10
20
5
10
0 0
0 20 40 60 80 100 120 140 160 180 200 0 5 10 15 20 25 30 35 40 45 50
t [ms]
t [ms]
KS
Figure 2: Analysis of arc burning time and short-circuit period.
Figure 3: Probability distribution of short-circuit period with CO2, Ar/CO2, and T.I.M.E shielding gases. I = 90 A, U = 21 V.
Figure 3 shows three diagrams indicating the Figure 5 shows the probability distribution only for the
differences in short-circuit periods with three differing welding current intensity but for three differing shielding
shielding gases but with the same other welding gases and with low (medium welding current intensity is
parameters. For pure-CO2 welding the variation of the 100 A) and high (medium welding current intensity is
curves during the short-circuit periods are smaller than 430 A) welding parameters. The occurrence of spatters
in the two other cases. Therefore it may be concluded primarily depends on the welding current intensity. The
that the welding process is more stable in this case than higher the welding current intensity in the short circuit,
in the other two cases. Two characteristics of the short- the stronger the pinch-effect force. Consequently,
circuit periods in T.I.M.E. are a large dissipation and breaking of the short-circuit bridge will be more
two extremes. They both reduce the welding-process explosive. The highest welding current intensities in the
stability. short circuit were obtained in welding with the T.I.M.E.
mixture (Figure 5 - left, below), and the lowest,
3.3 Probability distribution of voltage and current however, in welding with the pure CO2 (Figure 5 - left,
Evaluation of stationary random processes, i.e. of time- above). A stronger variation in the probability
varying welding current and voltage in our case, can be distribution with the high welding parameters and pure
performed also in the direction of ordinate x(t). In the CO2 (Figure 5 - right, above) occurs because there is no
direction of the ordinate x(t), a mean value mx, standard spray transfer in this case. Consequently, spattering is
deviation σx, and probability distribution p(x) can be stronger.
calculated as shown in Figure 4.
Figure 4: Evaluation of the process in the direction of ordinate x(t).
CO2
p [%]
Ar/CO2
p [%]
T.I.M.E.
p [%]
I [A] I [A]
Figure 5: Probability distribution p(I) with CO2, Ar/CO2, and T.I.M.E. shielding gases.
Left: I = 90 A, U = 21 V; Right: I = 420 A, U = 34 V.
S(ω
ω)
Ar/CO2
S(ω
ω)
T.I.M.E.
S(ω
ω)
ω [Hz] ω [Hz]
Figure 6: Energy spectra of a signal in welding with CO2, Ar/CO2, and T.I.M.E. shielding gases.
Left: I = 90 A, U = 21 V; Right: I = 420 A, U = 34 V.
3.5 Stability analysis based on a cyclogramme uncomplicated and fast presentation as far as the
Dynamic processes in the arc may be demonstrated also welding process stability is concerned. Monitoring of the
in another way, i.e., by cyclogrammes (dynamic process by means of a cyclogramme may be carried out
movement of the working point) in Figure 7. A in real time.
cyclogramme shows the welding voltage as a function of
the welding current intensity. Cyclogrammes are a very
In short-circuit transfer, two characteristic zones of the With an increase in welding current intensity, the U-I
U-I characteristic may be noticed in the cyclogramme. characteristic will displace to the upper right corner of
The arc burning zone is characterised by a higher the diagram, which means higher welding voltages and a
welding voltage and a lower welding current intensity, higher welding current intensity. In the case of Ar/CO2
and the short-circuit period by a low short-circuit voltage and T.I.M.E. mixtures, the spray transfer occurs. In pure
and a higher short-circuit intensity (Figure 7, left, above). CO2 welding, a smaller number of transfers from the arc
If the three left diagrams in Figure 7 are compared, a burning zone to the short-circuit zone may be observed.
greater stability is observed in welding with the pure CO2 This considerably reduces arc stability and essentially
(U-I characteristic occupies a smaller area). increases spattering.
CO2
ARC
U [V]
SHORT-
CIRCUIT
Ar/CO2
U [V]
T.I.M.E.
U [V]
I [A] I [A]
I [A] I [A]
Figure 7: Cyclogrammes for welding with CO2, Ar/CO2, and T.I.M.E. shielding gases.
Left: I = 90 A, U = 21 V; Right: I = 420 A, U = 34 V.
REFERENCES