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Fundamental understanding of the formation of cold laps with welding parameters and heat transfer in Tandem-arc MIG/MAG welding
Peigang Li Ph.D student Per Nyln Supervisor

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Tandem-arc MIG/MAG welding

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Base Metal

Base Metal

Welding Direction
Base Metal

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Quality of weld

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Quality of welds
Chemical Composition: P, S,
Mn, Si, Al; Mechanical Property: Tensile, Bend, Fatigue; Discontinuties:
Porosity; Lack of fusion; Lack of penetration; Crack; STD Undercut;

181- 0004
undercut

Cold lap; life

Geometry;

Fatigue

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Cold laps

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Definition of Cold laps Small lack of fusion at weld toe. (KOST/LOST)

Small (typically < 0,5 mm), Difficult to be detected by common NDT methods. Initiate fatigue failure and thus decrease severely the fatigue life of welds. Recent study classify it into: Spatter cold lap, overlap.

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Hypothesis of formation of cold laps

Wire Shield Gas Arc Melted metal (hot) Melted metal (cold)
Volatge; Current (Wire feed speed); Welding speed; Angle factor; Etc. Temperature; Interface substance;

Welding process

Heat Transfer

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Experiment
Welding Direction TC2 150mm 30mm 30mm TC1 12mm TC3

Thermal couple

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Welding Parameters
Run Ord. 1
2 3 4 5 6 7 8 Welding Master Ratio Speed Voltage of (mm/s) (V) voltage Slave voltage (V) Wire feed speed* (m/min)

level Parameters Ratio of voltage (%) Welding Speed (mm/s) 0,8 11 + 1,2 17

14
14 14 11 17 17 17 11

29.65
29.65 29.65 28.3 31 28.3 31 31

1
1 1 0.8 1.2 0.8 0.8 0.8

29.65
29.65 29.65 22.64 37.2 22.64 24.8 24.8

11.5
11.5 11.5 9 14 14 9 14

Master Voltage (V)

Wire Feed Speed (m/min)

28,3
9

31
14

9
10 11

17
11 11

28.3
31 28.3

1.2
1.2 1.2

33.96
37.2 33.96

9
9 14

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Collected Data

Welding Voltage (V), Welding Current (I), Thermal Couple 1, 2, 3 (TC1, TC2,
TC3),

High speed Camera Video, Infrared Camera

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I,V,TC1,TC2,TC3

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IR Camera
Line scanning at the Thermal couple

(TC) position.
Peak Temperature in weld pool. Peak Temperature in of TC.

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Synchronization
Synchronization is important to link the measurements with the other detector of the welding process, e.g. High Speed Video(Locating the high speed video).

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Next Step
Detecting of cold laps; Metallography sample; EDS (chemical composition test).
MT? RT? Destructive Test??......

Statistical analysis of the collected data and response;

Future Works
Qualitative study about the empirical relationship between

welding parameters and cold laps;

Quantitative study for cold laps and parameters; Controlling parameters.

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Tack

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