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KEY W O R D S
Metal Transfer
SMAW
Electrodes
Analysis
Modeling
Explosive Transfer
Short-Circuiting Transfer
Slag-Guided Transfer
Polarity
Current
Low current C M A
C 0 2 shielded C M A
Projected
Streaming
Rotating
Explosive
Intermediate-current GMA
Medium-current GMA
High-current GMA
SMA (Coated electrodes)
Bridging transfer
Short-circuiting
Bridging without interruption
Short-arc GMA
Welding with filler wire addition
Slag-protected transfer
Flux-wall guided
Other modes
SAW
SMA, Cored-wire, Electroslag
Spray
DCEP
DCEN
Shielding
Gas
Low
CO2 type
short-circuiting. Becken (Refs. 27, 28) further discussed the interaction of surface
tension forces (75|ag and 7metai) with the
cathode spot pressure, both responsible
for droplet transfer. Besides, there is also
evidence of liquid metal flow inside the
molten electrode tip (Refs. 2, 5, 7, 9, 27,
29-32), which affect the metal transfer
behavior. The hydrodynamic instability of
Molten
Slag
Droplet
Size
(SC)-E
(SC)-E
SC-E
Small
Medium
Large
Forces
Present(c)
S,V,G
S,V,G
S,V,G
Metal
Droplet
ectric
Gravitational
Force
Flux
Coating,
Molten
Electrode
Tip
Type <b)
(a) DCEP-direct current electrode positive; DCEN direct current electrode negative.
(b) (SC)limited short-circuiting transfer; SC - short-circuiting transfer; E-explosive transfer.
(c) Ssurface tension; V vapor pressure; C-gas expansion force.
Electrode
Core
Fig. 7 Schematic
drawing of a molten
electrode tip
illustrating the
different forces
involved in metal
droplet transfer
during welding.
Transfer Characteristics
Current
Density
t h e transfer b e h a v i o r . A t t e m p t s h a v e also
b e e n m a d e t o use acoustic signals t o
m o n i t o r metal transfer (Refs. 55, 56).
Table 3 c o m p a r e s the d i f f e r e n t t e c h niques used in o b s e r v i n g metal transfer in
S M A w e l d i n g . Each m e t h o d has its o w n
advantages a n d shortcomings. D i r e c t o b servations, h o w e v e r , are generally p r e f e r r e d . D e s p i t e t h e f a i r - t o - g o o d optical
resolution that can b e o b t a i n e d b y p h o t o g r a p h y , high-speed
cinematography
a n d high-speed v i d e o , t h e t i m e o f each
sampling ( p e r i o d of active arc o b s e r v a tion) is generally limited t o a f e w seconds
or less, thus requiring a large n u m b e r of
samples f o r statistical significance. Indirect
m e t h o d s are generally c o n d u c t e d as w e l d
simulations that d o not actually c o r r e s p o n d t o a real w e l d i n g situation. Theref o r e , it is n o t unusual t o c o m b i n e several
of t h e direct a n d indirect techniques t o
characterize the p r e d o m i n a t i n g metal
transfer m o d e in a w e l d i n g process.
Table 3Comparison of the Different Techniques Used in Observing Metal Droplet Transfer
Techniques
Advantages
Photography
Deposition on metal
plates
O b j e c t i v e s o f this R e s e a r c h
T h e main o b j e c t i v e of this w o r k was t o
characterize metal transfer in S M A w e l d ing b y studying t h e metal d r o p l e t s collected during w e l d i n g . The effect o f w e l d ing process parameters (current, polarity
a n d position) a n d e l e c t r o d e c o n d i t i o n s
( c o m p o s i t i o n and diameter) o n the size of
the droplets transferred a n d the a m o u n t
of spatter w e r e investigated. It is anticip a t e d that: 1) the m e t h o d o l o g y established in this research can b e used t o evaluate the p e r f o r m a n c e of c o m m e r c i a l and
experimental electrodes; a n d 2) the k n o w l e d g e gained in this study c a n b e used t o
i m p r o v e shielded metal arc w e l d i n g p r o cess c o n t r o l w i t h s m o o t h metal d r o p l e t
transfer a n d m i n i m u m spatter.
Double electrode
Carbon electrode
Disadvantages
Complex experimental setup
Short sampling time
Imprecise droplet size
measurement
Incapable of distinguishing droplet
from slag covering
Short sampling time
Imprecise droplet size
measurement
Incapable of distinguishing droplet
from slag covering
Indirect observation and
correlation
Transfer event difficult to
characterize
Incapable of droplet size and
shape determination
Incapable of distinguishing droplet
from slag covering
Simulated welding
Droplet may coalesce or fracture
at contact with chill
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Simulated welding
AC welding
Electrodes covered by slag
Simulated welding
Oxidation of the carbon electrode
causing changes in arc
atmosphere
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Experimental Procedure
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A rectifier-type p o w e r supply a n d an
a u t o m a t e d S M A w e l d i n g system (Ref. 57)
w e r e used t o p e r f o r m the w e l d i n g experiments w i t h c o m m e r c i a l A W S E6011,
E6013, and E7018 grade c o v e r e d elect r o d e s . The d e p o s i t i o n w a s m a d e against
a rotating c o p p e r disk as s h o w n in Fig. 2.
T h e metal d r o p l e t s w e r e e j e c t e d b y the
spinning disk i n t o c o l d w a t e r . T h e r o t a t i o n
speed of the c o p p e r disk w a s fixed at 890
r p m because at that s p e e d , n o metal
d r o p l e t was o b s e r v e d t o coalesce or
f r a g m e n t (Ref. 57) d u r i n g c o n t a c t w i t h the
disk. A f t e r the transferred d r o p l e t s w e r e
d r i e d , the slag coverings w e r e separated
b y h a n d crushing w i t h a m o r t a r a n d pestle. T h e metal d r o p l e t s w e r e t h e n m a g netically separated f r o m the slag particles.
The samples a c q u i r e d using a splitter w e r e
classified a c c o r d i n g t o size f o l l o w i n g stand a r d particulate processing techniques
(ASTM Standard B-215). U.S. sieve series
(ASTM) n u m b e r 5 , 7 , 1 0 , 1 4 , 1 8 , 20 a n d 35,
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Fig. 2-Welding
equipment setup showing the SMA electrode and the rotating copper disk.
Fig. 3 Material deposited from a shielded metal arc welding electrode. A Metal droplets, metal droplets covered with slag, and slag particles; B me
droplets after slag removal.
50 CD
CD
40 -
OL.
co
u
30 -
D
Q_
20 CD
E
-3
10 -
1
2
3
4
Diameter of Droplets ( m m )
Fig. 4 Metal size distribution determined for Experiment A to illustrate the larger number of small With the mean apparent density values
(dg), the total mass (m) and number of the
particles generated by an E6011 electrode.
droplets retained in each sieve (n), the average diameter (D) of the droplets in each
sieve was determined using the equation
below.
D
THMT
|_7tndgJ
Amount of Spatter
ZNjVi2
U)
SNiVi
>/3
(3)
-(
Electrode diameter
(A)
Welding current
(B)
Welding position
(C)
Polarity
(D)
Low Level
High Level
4 mm
5 mm
150 A
200 A
Flat
Nonflat
a
DCEP< '
Experiment
Designation
Electrode
Diameter
(mm)
Welding
Current
(A)
Welding
Position
Polar-
-A4
5
4
5
4
5
4
5
4
5
4
5
4
5
4
5
-B150
150
200
200
150
150
200
200
150
150
200
200
150
150
200
200
-C-
I
A
B
AB
C
AC
BC
ABC
D
AD
BD
ABD
CD
ACD
BCD
ABCD
-D+(b)
As indicated earlier, weld spatter is related to the stability of the welding arc and
metal transfer. Experimental observations
showed that these fine metal droplets
were between 500 /um (+20 mesh) and
212 /um (70 mesh) in size. Therefore, the
total number of droplets within the above
size range, assumed to be the total amount
of spatter, were counted and reported in
Table 8. Of the three electrodes, welding
with E6013 grade electrodes resulted in
the smallest amount of spatter, independent of the welding conditions Fig. 5.
The effects of welding parameters on
spatter will be discussed in the section on
analysis of variance (ANOVA) results.
ity
plal
+
+
+
F
F
F
HW
H
H
H
F
F
F
F
H
H
H
H
+
+
+
+
-(b)
Table 6Mean Apparent Density (g/cm3) and Mean Apparent Porosity (%) as a Function of
Electrode Coating and USA Sieve Series (Ref. 67)
E6011
5.73
6.75
7.32
7.45
0.76
0.40
0.13
0.28
2.98
4.33
6.04
7.27
7.47
(%)
E7018
E6013
5
7
10
14
18
Range of Study
Main Variables
(1)
The characteristic volume (Vc) of the droplets for each experiment, as defined in the
following equation (Refs. 40, 41),
3.84
4.83
6.49
7.29
7.48
0.27
0.39
0.32
0.27
0.22
0.22
0.32
0.29
0.15
0.20
E6011
27.10
14.12
6.87
5.22
E6013
E7018
62.09
44.91
23.16
7.51
4.96
51.15
38.55
17.43
7.25
4.83
DCEN<a>
Table 7Summary of the Analysis of Variance Results of the Characteristic Diameters of the
Droplets (Ref. 57)
Mean Characteristic
Diameter (mm)
Experiment
1
A
B
AB
AC
BC
ABC
D
AD
BD
ABD
CD
ACD
BCD
ABCD
Estimated Effects'1'
Estimated F0
E6011
E6013
E7018
E6011
2.15
2.05
1.85
1.92
1.84
2.29
1.89
1.86
1.59
1.60
1.65
1.60
1.65
1.94
1.51
1.73
2.48
2.59
2.01
2.01
2.18
2.55
1.84
2.26
2.00
2.04
2.06
2.02
2.38
2.60
1.99
1.90
2.85
3.34
2.37
3.37
2.12
3.21
2.42
2.92
3.08
3.17
3.06
3.21
2.98
3.89
2.49
3.04
_
7.02
10.97
1.76
<1
8.80
1.14
4.01
60.81
<1
2.55
<1
2.13
<1
1.96
3.77
E7018
E6011
E6013
E7018
10.62
73.09
1.88
2.53
6.27
4.79
<1
8.67
5.65
4.00
1.18
9.82
3.05
23.67
1.55
177.95
23.98
1.05
14.73
13.17
5.91
18.23
41.71
15.27
6.11
<1
10.13
9.61
25.79
3.67
1.82
0.1100 d
-0.1375b
2.18
0.1294 b
-0.3394 a
2.97
0.5984 a
-0.2197 a
E6013
0.1231
-0.3238 a
0.0994
-0.1169c
0.1244 c
-0.19312
-0.1722b
0.1628 b
-0.1091d
-0.1916 a
0.2897a
-0.1753b
-0.1109d
0.1428 c
0.1391 c
-0.2278 a
Table 8Summary of the Analysis of Variance Results of the Amount of Spatter (Ref. 57)
Mean Spatter
(Number of Droplets)
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Estimated FD
Estimated Effects'1'
Experiment
E6011
E6013
E7018
E6011
1
A
B
AB
C
AC
BC
ABC
D
1886
1052
1780
1119
1976
1276
2324
1661
2654
2638
3453
2847
3021
1789
3538
2018
576
504
1010
962
1016
684
1503
1152
1191
940
1338
1474
993
1209
1394
1139
1170
1288
1424
688
1149
783
1310
1013
1508
883
869
873
981
1115
1234
986
56.20
8.70
<1
<1
5.79
<1
<1
114.28
<1
1.63
1.71
9.99
7.41
1.55
<1
2.59
23.13
2189
-778.25 a
306.34c
Al)
BD
ABD
CD
ACD
BCD
ABCD
<1
3.39
<1
<1
2.31
14.59
1.20
1.97
<1
6.45
1.16
<1
1.88
12.30
<1
< I
<1
<1
6.90
<1
<1
<1
<1
3.22
<1
< I
<l
11.32
E6013
1068
Electrode Type
E7018
1080
-252.10b
357.53 a
Electrode
diameter
(mm)
1110.59a
283.96 b
-328.29 c
-282.85d
-188.79 d
Welding
current
(A)
OC
-241,85
Welding
position
Polarity
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E6011
V E6013
T E7018
3500
E7018
1.79
0.18
2.17
0.29
5.0
1.64
0.19
1.70
0.12
2.08
0.16
1.82
0.14
2.98
0.15
2.44
0.40
1.59
0.06
1.53
0.05
1.91
0.18
1.68
0.23
2.68
0.36
2.52
0.42
1.70
0.13
1.73
0.18
1.59
0.08
2.03
0.36
1.93
0.25
1.96 +
0.37
2.50
0.45
2.60
0.32
2.66
0.38
I 50
200
4000
<
E6013
1.63
0.08
188.84 d
E6011
4.0
Flat
Nonflat
DCRP
DCSP
3000
Flux Coating Cup (Arc Barrel) at the
Electrode Tip
_Q
UJ
2000
<u
1500
Q.
2500
At t h e e n d o f each w e l d i n g e x p e r i m e n t ,
the tip o f t h e e l e c t r o d e w a s also e x a m i n e d
to d e t e r m i n e t h e presence of porosity in
the u n d e t a c h e d m o l t e n metal d r o p l e t a n d
the c u p o f flux coating (arc barrel) f o r m e d
at t h e t i p o f t h e e l e c t r o d e d u r i n g w e l d i n g ,
as s h o w n in Fig. 6. T o a v o i d breakage o f
the c u p , t h e e l e c t r o d e tip w a s first filled
w i t h adhesive a n d m o u n t e d in resin. Careful sectioning o f the e l e c t r o d e tip along a
diametral plane a n d light grinding revealed
the features described a b o v e . T h e d e p t h
of t h e cups w e r e m e a s u r e d using an o p tical p r o f i l o m e t e r . A schematic profile o f
the t i p o f a S M A e l e c t r o d e is also s h o w n
in Fig. 6. Table 9 s h o w s t h e average c u p
depths f o r the three electrodes investig a t e d . As e x p e c t e d , basic electrodes such
as E7018 s h o w e d the deepest c u p . This
can b e related t o t h e chemical c o m p o s i t i o n a n d viscosity o f t h e flux coating a n d
the thickness o f t h e coatings. It is also i m p o r t a n t t o notice t h e presence o f a large
internal p o r o s i t y in the metal d r o p l e t in Fig.
6. This seems t o s u p p o r t Larson's m o d e l o f
gas expansion leading t o metal d r o p l e t
transfer.
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1000
500
D AD BD CD BCD
1 A B AB C AC BC
ABC
ABD ACD ABCD
Experiment Designation
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results of Experiment 1. The number between brackets indicates the relative order of significance of the experiment;
smaller numbers represent tests more
heavily influenced by the specific welding
conditions. Note that the order of significance for each one of the three types of
electrode coating is not necessarily the
same.
Polarity Effect (Experiment D)
In the case of E6011 and E6013 grade
electrodes, a change in polarity, from
electrode positive (reverse) to electrode
negative (straight), caused a decrease in
the characteristic diameter of the metal
droplets and an increase in the amount of
spatter. This can be related to the surface
temperature of the metal droplets (Refs.
E6011
Significant
Experiments
Characteristic
Diameter
Amount of
Spatter
D
B
AC
A
CD
ACD
BCD
AD
C
BD
BC
ABC
ABCD
1 (Dw
t (1)
t (4)
i (2)
t (3)
t (4)
1 (2)
1 (3)
1 (5)
Characteristic
Diameter
1
1
t
t
t
(5)
(1)
(6)
(3)
(4)
1 (2)
E7018
Amount of
Spatter
t (2)
t (1)
1 (3)
Characteristic
Diameter
t
i
t
t
t
t
i
(2)
(4)
(8)
(1)
(9)
(10)
(3)
1 (6)
1 (7)
i (11)
1 (12)
i (5)
Amount of
Spatter
1 (1)
t (3)
t (2)
I
...i,..,5jj\
'
/ffj:
(")
(1536C)
Metal Droplet
Droplet
Surfoce "
(2000C)
Anode Spot
(40O0C)
Electric Arc
(4000C)
Spot
6000C)
(+)
Fig. y /ts a result of fluoride ions (F~) migrating to the anode and reacting with the layer of fig. 10-Metal vapor pressure (Fj), electromagnetic
positive charges there, the cathode size is reduced.
pinch force (FJ, and liquid circulation within the molten droplet generate compressive forces which cause
the droplet to explode at the moment of shortcircuiting.
Conclusions
T h e m a j o r findings of this w o r k are
s u m m a r i z e d in the f o l l o w i n g conclusions:
1) Explosive, short-circuiting a n d slagg u i d e d w e r e the t h r e e transfer m o d e s
o b s e r v e d in S M A w e l d i n g w i t h E6011,
E6013 a n d E7018 grade electrodes.
2) Explosive transfer w a s the p r e d o m inate mechanism, e v i d e n c e d b y the hete r o g e n e o u s size distribution of the d r o p lets f o r all experiments.
3) Slag-protected transfer w a s most
significant in w e l d i n g w i t h E7018 grade
electrodes, w i t h a large n u m b e r of t h e
d r o p l e t s c o v e r e d entirely b y slag.
4) Polarity w a s the variable that most
a f f e c t e d t h e size o f the d r o p l e t s transf e r r e d , as w e l l as the a m o u n t o f spatter f o r
w e l d i n g E6011 grade electrodes.
5) For E7018 grade electrodes, polarity
has an o p p o s i t e effect o n characteristic
diameters o f the droplets transferred. This
is d u e t o t h e flux coating c o m p o s i t i o n
(presence of f l u o r i d e ions) a n d chemical
reactions that o c c u r b e t w e e n t h e metal
a n d m o l t e n slag at t h e tip o f the e l e c t r o d e .
6) C u r r e n t w a s t h e variable that most
a f f e c t e d t h e size o f the d r o p l e t s transf e r r e d , as w e l l as t h e a m o u n t of spatter f o r
w e l d i n g w i t h E6013 grade electrodes.
7) Electrode d i a m e t e r w a s t h e variable
that most a f f e c t e d the size of the d r o p l e t s
transferred, as w e l l as t h e a m o u n t o f
spatter f o r w e l d i n g w i t h E7018 grade
electrodes.
8) E6013 electrodes p r o d u c e d the most
stable arc w i t h l o w spatter because of t h e
relatively small d r o p l e t size transferred.
9) Porosity in t h e m o l t e n e l e c t r o d e tip
was d e t e c t e d in all t h r e e electrodes, being
m o r e f r e q u e n t l y o b s e r v e d in the E6013
and E7018 electrodes.
10) I n d e p e n d e n t o f t h e t y p e o f w e l d ing e l e c t r o d e , small characteristic diameters w e r e o b s e r v e d w h e n d r o p l e t s e x p l o sion p r e c e d e d t h e transfer. If droplets exp l o d e d after short-circuiting w i t h t h e w e l d
p o o l , the characteristic diameters w e r e
generally bigger.
A ckno wledgments
The authors a c k n o w l e d g e and a p p r e c i ate t h e research s u p p o r t o f FAPESP (Fund a c a o de A m p a r o a Pesquisa d o Estado d e
Sao Paulo, Brazil) a n d the help of Eloi Patinetti F in the e x p e r i m e n t a t i o n of this
w o r k . O n e o f the authors, S. Liu, also acknowledges the support of the Welding
Research C o u n c i l .
References
1. IIW. (1977) Classification des Divers
Modes de Transfert du Metal en Soudage a
I'Arc. IIW D O C XII-535-77.
2. Adrichem, Th. ). van. 1969. Metal Transfer. IIW DOC 212-171-69.
3. Schellhase, M. 1980. Der Schweisslicht-
59. Duckworth, W . E. 1962 Statistical Techniquesin Technological Research. 1st Ed, Metheuen & Co. Ltd.
60. Natrella, M. C. 1962. Experimental Statistics. 1st Ed., NIST.
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