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EnergyProcedia
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2018 The Fourth International Symposium on Hydrogen Energy, Renewable Energy and
2018 The Fourth International
Materials, HEREMSymposium 13-15onJune
2018, 13 Hydrogen Energy, Renewable
2018, Bangkok, Thailand Energy and
Materials, HEREM 2018, 13 13-15 June 2018, Bangkok, Thailand
Investigation of hot-wire wire TIG welding based on the heat-
Investigation of hot-wirewire
The 15th International TIG welding
Symposium basedand
on District Heating onCooling
the heat-
conduction
Assessing the feasibilitya,b conduction
of using
a,
the heat demand-outdoor
c
Fujun Caoa,b, Shujin
hujin Chena,*, Chengchao Duc
Fujun Cao , Shujin
hujin Chen *, Chengchao Du
temperature function
School
a
a
forUniversity
of matierial,, Jangsu a long-term district
of Science and Technology, heat
Zhenjiang demand
212000, China forecast
b
Schooland
Research of matierial,
, Jangsu
development University
department, of Science
Seksun and Technology, Zhenjiang
Technology(suzhou)Co.,Ltd, 212000,
Suzhou China
215000, China
b
Research
c
andofdevelopment
School
a,b,c power and department,engineering,
mechanical Seksun Technology(suzhou)Co.,Ltd,
Wuhan University, WuhanSuzhou 215000,
430072, ChinaChina
I. Andrić c *, A. Pina , P. Ferrão , J. Fournier ., B. Lacarrière , O. Le Correc
a a b
School of power and mechanical engineering, Wuhan University, Wuhan 430072, China
c

a
IN+ Center for Innovation, Technology and Policy Research - Instituto Superior Técnico, Av. Rovisco Pais 1, 1049-001 Lisbon, Portugal
Abstract b
Veolia Recherche & Innovation, 291 Avenue Dreyfous Daniel, 78520 Limay, France
Abstract cDépartement Systèmes Énergétiques et Environnement - IMT Atlantique, 4 rue Alfred Kastler, 44300 Nantes, France
The hot-wirewire TIG welding equipment was built based on the heat heat-conduction
conduction method. The temperature-
temperature
The hot-wire
controlling wire was
model TIGdeveloped
welding and equipment
verifiedwas
withinbuilt based temperature
a certain on the heat
heat-conduction
conduction
ran
range. method.
ge. The results The that
showed temperature-
temperature
the wire
controlling model was developed and verified within a certain temperature
temperature could be maintained at 220±5°C. The comparing experiments between the hot ran
range.
ge. The results showed
wire TIGthe
hot-wire that wirea
with
Abstract
temperature could be maintained at 220±5°C. The comparing experiments between the
temperature of 220 °C and ordinary TIG were conducted. The results showed that the hot wire TIG based on thea
hot
hot-wire
hot-wire wire TIG with
temperature
heat-conduction of
duction 220 °C and
method could ordinary TIG were
improve addressed conducted.
the appearance and The results
the feeding showed
speed. that
When the hot
hot-wire
wire TIG
the appearance wasbased on the
similar, the
District duction
heating networks
heat-conduction method are commonly
could improve the in the and
appearance literature
the as one of
feeding the most
speed. When effective
the solutions was
appearance for decreasing
similar, the
the
efficiency of hot-wire TIG in root welding was doubled compared with that of the ordinary TIG.
greenhouse gas emissions from the building sector. These systems require high investments which are returned through the heat The efficiency of
efficiency
hot-wire of hot-wire
TIG TIG in wasroot weldingcompared
was doubledwith compared of thewith that of the Moreover,
ordinary TIG. The efficiency of
sales. Due to in
thecap welding
changed climate tripled
conditions and building that
renovation ordinary
policies, TIG.
heat demand in thethe microstructure
future of
could decrease,
hot-wire
welding TIG
seam
prolonging
in
the of
cap welding
the hot-wire
investment wire was
returnTIG
tripled compared with that of the ordinary TIG. Moreover, the
welding was finer than that of the ordinary TIG welding. The hardness of welding
period.
microstructure of
welding
seam of seam
The main the
scope ofofthe
thishot-wire
hot-wire
wire wire
TIG
paper is TIG
welding welding
to assesswas was finer
the harder ofthan
than
feasibility that that
using of of
heatthe
the the ordinary
ordinary
demand –TIG TIG welding.
welding
outdoor Thefunction
hardness
slightly.
temperature of welding
Goodformechanical
heat demand
seam of
properties the hot-wire
of the
forecast. The wire TIG
two joints
district welding
have been
of Alvalade, was harder
indicated.
located than that
. The(Portugal),
in Lisbon of
fracture was the ordinary
was located TIG
used asina the welding
caseASTM slightly.
study. A106 Good
base metal.
The district mechanical
is consisted of 665
properties of the
buildings that twoin joints
vary have been indicated.
both construction . The
period and fracture
typology. wasweather
Three locatedscenarios
in the ASTM(low, A106
medium,base metal.
high) and three district
©renovation
2018 The Authors.
scenariosPublished by Elsevier
were developed Ltd. intermediate, deep). To estimate the error, obtained heat demand values were
(shallow,
Copyright
© 2018 The ©Authors.
2018 ThePublished
Authors. by
Published
Elsevierby Elsevier Ltd.
Selection heatLtd.
Selection and peer-review under responsibility of
and review
peer-review under responsibility of the
the scientific
scientific committee
committee ofof the 2018
compared with results from a dynamic demand model, previously developed andThe Fourthby
validated International
the authors.Symposium on
the 2018 The Fourth International Symposium on
Selection
Hydrogen and
The resultsEnergy,
showed review
peer-review
Renewableunder
that when responsibility
Energy
only of the scientific
and Materials.
Materials.
weather change committee
is considered, of theof
the margin 2018 The
error Fourth
could International
be acceptable forSymposium on
some applications
Hydrogen Energy, Renewable Energy and
Hydrogen
(the errorEnergy, Renewable
in annual demand Energy
was lowerandthan
Materials.
20% for all weather scenarios considered). However, after introducing renovation
scenarios,heat-conduction;
Keywords: the error valuehot-wire
wire TIG;up
increased welding efficiency;
to 59.5% microstructure;
(depending on the mechanical
weather and property
property;
renovation scenarios combination considered).
Keywords:
1.
The heat-conduction;
Introduction
value hot-wire
of slope coefficientwire increased
TIG; welding
onefficiency; microstructure;
average within mechanical
TIG
the range property
property;
ofwelding,
3.8% up tothe8%efficiency
per decade,isthathigher [1,2], toand
corresponds the
1.decrease
Introduction
in the number of heating hours of 22-139h during the heating TIG welding,
season
appearance the efficiency
(depending
is improved on[3,4]. is higherof
the combination
Therefore, [1,2],
theweather and
hot-wireand
wire
renovation scenarios
wire
Hot-wire considered).
TIG welding is aOnTIGthe welding
other hand, function
using  appearance
intercept
TIG weldingis is
increased improved
for [3,4].
7.8-12.7%
widely usedperinTherefore,
decade the
of hot-wire
(depending
the field wire
on
pressure the

coupled wire
Hot-wire TIG
scenarios). welding
The valuesis a TIG
suggested welding
could
pre-heating wire. When compared with the traditional beusing
used
ional to modify TIG
the welding
function is widely
parameters used
for thein the field
scenarios of pressure
considered,
vessels fabrication and ship building. Currently, there and
improve thewire.
pre-heating accuracy
When of heat demandwith
compared estimations.
the traditional
ional vessels fabrication and ship building. Currently, there
are three methods for wire heating, including
are three heating,
resistance methods for wire
induction heating,
heating, and arcincluding
heating
© 2017 The Authors. Published by Elsevier Ltd. resistance heating, induction heating, and arc heating
Peer-review under responsibility of the Scientific Committee of The 15th International Symposium on District Heating and heat
[5]. Among
mong them, resistance heating uses the
Corresponding author. Tel.: +86 159 0528 7016. E-mail [5]. Among
mong them, resistance heating uses the
product from the current across the wire. Compared heat
 Cooling.
address: chenshujin7120@126.com
Corresponding author. Tel.: +86 159 0528 7016. E-mail product from the current across the wire. Compared
address: chenshujin7120@126.com
Keywords: Heat demand; Forecast; Climate change
1876-6102© 2018 The Authors. Published by Elsevier Ltd.
1876-6102©
Selection and2018 The Authors.
review
peer-review under Published by Elsevier
responsibility Ltd.
of the scientific committee of the 2018 The Fourth International Symposium on Hydrogen Energy,
Selection
Renewableand peer-review
Energy review under responsibility of the scientific committee of the 2018 The Fourth International Symposium on Hydrogen Energy,
and Materials.
Renewable Energy and Materials.
1876-6102 © 2017 The Authors. Published by Elsevier Ltd.
Peer-review under responsibility of the Scientific Committee of The 15th International Symposium on District Heating and Cooling.
1876-6102 Copyright © 2018 The Authors. Published by Elsevier Ltd.
Selection and peer-review under responsibility of the scientific committee of the 2018 The Fourth International Symposium on Hydrogen
Energy, Renewable Energy and Materials
10.1016/j.egypro.2018.06.003
10 Fujun Cao et al. / Energy Procedia 144 (2018) 9–15
2 Author name / Energy Procedia 00 (2018) 000–000

with the other two methods, the heating equipment is
simple, low-cost, and easy setting. However, the
magnetic bias and arc phenomenon of welding arc
always occurred during welding. Moreover, the
optimal parameters of hot-wire power are also
difficult to be obtained [6,7]. Fan [8] et al designed
the wire-heating equipment based on the high
frequency induction method. The induction
frequency and coil inductor were taken into
consideration. Therefore, the parameters for hot-wire
TIG welding was more and more complex.
In this investigation, the hot-wire TIG welding
based on the heat-conduction method was designed.
In the investigation, an automatic welding
machine has been used, and all the welding process
was automatic.
The heating tube with an internal diameter of 1.2
mm was designed. The tube was located near the end
of welding torch. The welding wire with a diameter
of 1.2 mm passed through the heating tube. The
heated wire was driven to the arc by the wire feeder.
Lastly, the wire melted with the function of arc-
heating and wire pre-heating. The schematic is shown
in Fig. 1.
Wire

It avoided the disadvantages from the resistance Power

Tungsten
heating method. The pre-heating temperature of the electrode Wire-heating
welding wire was controlled effectively based on the Arc equipment
mathematical model of temperature control. When Molten
compared with the high frequency induction method, pool Base metal

the equipment of heat-conduction method was easy to

be operated and was low-cost. It is applicable during
the pipe welding. The comparing study between hot-
wire TIG and the ordinary TIG was also conducted. Fig. 1. The schematic of the hot-wire TIG.
The advantages of the hot-wire TIG welding were
obtained based on these investigations, including The wire-heating equipment is shown in Fig. 2.
appearance, microstructure, and mechanical The welding torch and heating equipment are shown
properties. in Fig. 2 (a). The temperature controller is shown in
Fig. 2 (b). The welding wire passing through the
2. Equipment, materials, and methods heating-tube was heated by the heat-conduction
method.
2.1. Hot-wire TIG welding equipment

Fig. 2. Equipment of hot-wire TIG welding, (a) welding torch and heater, (b) temperature controller.

2.2. Mathematical model of the temperature 300

controller
Wire temperature, ℃

250
Data1 Data2 Data3 Data4 220℃
Target temperaturet
In this investigation, the temperature sensor only 200

detected the temperature of the heater. Therefore, the 150

Heater temperature
200℃

wire temperature as a function of welding speed was 100

300℃
400℃

measured with a special temperature of heater as 500℃

600℃
shown in Fig. 3. The wire temperature is steadily 50
0 500 1000 1500 2000 2500 3000 3500
W ire feeding speed,mm/min
decreasing over the whole range of tested feeding
speed. Fig. 3. Wire temperature as a function of feeding speed.
 Fujun Cao et al. / Energy Procedia 144 (2018) 9–15 11
Author name / EnergyProcedia 00 (2018) 000–000 3

When setting the wire temperature at 220 °C, welding wire was maintained at 220 °C by the
the Data1 (the temperature of heater was 300 °C), the heating of heater. The results showed that the error
Data2 (the temperature of heater was 400 °C),the was only 5 °C when the feeding speed ranging within
Data3 (the temperature of heater was 500 °C), and 3500 mm/min.
the Data4 (the temperature of heater was 600 °C)
were obtained. After fitting by MATLAB software, 2.3. Materials and experiments
the mathematical model between the temperature of
heater and the feeding speed was derived as shown in The effect of wire temperature on the deposited
Fig. 4. The linear relationship is as following: metal was investigated based on the cladding process
T=0.1533v+252.1 （1） on the surface of A106 steel pipe. The diameter of the
welding wire (TM-56) was 1.2 mm. The shielding
where v is the feeding speed, T is the temperature of gas was pure Argon (99.99%) with a flow of 15～
heater. 20L/min. The parameters of the cladding process are
800
shown in Table 1. When comparing the
Heater temperature(T), ℃

700
microstructure and mechanical properties from the
hot-wire TIG welding and ordinary TIG welding, the
600 T=0.1533*v+252.1

Data4
500
welding parameters are shown in Table 2. Fig.5
400
Data3
shows the schematic of the welding joint.
300
Data2 60°
Data1
200
0 500 1000 1500 2000 2500 3000 3500
W ire feeding speed(v), mm/min Cap welding

8.18mm
Pipe Pipe
Fig. 4. Temperature heater as a function of feeding speed.
Filling welding

Based on the above mathematical model, the Root welding

1-2mm
heater temperature could be calculated by pre-setting
a feeding speed before welding. The temperature of Fig. 5. Schematic of dimension and welding of joint.

Table 1. Parameters of cladding.

Wire Feeding Welding
Welding Current, Voltage, Frequency, Hz/
temperature, speed, speed,
method A V Amplitude, mm
℃ mm/min mm/min
Cladding 25～250 200 13 2400 140 160/5

Table 2. Parameters of root welding, filling welding, and cap welding.

Wire Feeding Welding

Current, Voltage, Frequency, Hz/
speed, speed,
temperature, ℃ A V Amplitude, mm
mm/min mm/min
Root 160 13 1000 90 120/2
25 Filling 200 13 1600 110 120/4
Cap 200 13 1600 110 160/6
Root 160 13 2000 160 120/2
220 Filling 200 13 3200 220 120/4
Cap 200 13 3200 220 160/6
The cross-section of the joint was pre-grinded by the wire-electrode cutting. The welding seam
and polished. The cross-section was etched by the located in the middle of tensile sample. The tensile
alcohol with a HNO3 concentration of 4vol. %. Then test was performed on the electronic universal testing
the cross-section was observed by the optical machine with a tensile speed of 0.5 mm/s.
microscopy. The hardness was tested by the micro-
hardness tester. The load was 200 g. The holding 3. Results and discussions
time of the maximum load was 5 s. There was a
distance of 2 mm from the inner side of the pipe to 3.1. Effect of wire temperature on the process of TIG
the test location. The tensile sample was fabricated welding
12 Fujun Cao et al. / Energy Procedia 144 (2018) 9–15
4 Author name / Energy Procedia 00 (2018) 000–000
The weld width and weld reinforcement as a
function of wire temperature are shown in Fig. 6. The
weld width increases from 12.4 mm to 13.3 mm
when the wire temperature increases from 25 °C to
250 °C. On the other hand, the weld reinforcement
decreases from 2.2 mm to 1.7 mm. It means that the
hot-wire benefits to the spread of the cladding metal
on the surface of the base metal. Therefore, the weld
width increases gradually, on the contrary, the weld
reinforcement decreases gradually.
15
14
Weld width, mm
13
12
11
10
0 50 100 150 200
Wire temperature, ℃
250
Fig. 6. Weld width and weld reinforcement as a function of the
wire temperature.
The appearances of the cladding layer with the
wire temperature of 25 °C and 250 °C are shown in
Fig. 7. It could be seen from the Fig. 7 that the weld
line was more uniform when the wire temperature
was increased.
Fig. 7. Welding appearances of the cladding layer.
It could be concluded from the above results that
the advantages of the hot-wire TIG welding would be
improved when the wire temperature was increased.
Fig. 8. (a) and (b) the acceptable welding parameters, (c) appearance of the root welding.
3.2. Microstructure and mechanical properties of hot-
wire TIG welding
In order to compare the hot-wire TIG welding in
However, in order to apply this hot-wire TIG welding
in more situations, especially in the manual TIG
welding, the wire temperature of 220 °C was chosen.
The temperature could also reduce the damage to
operator.
In order to investigate the effect of hot-wire on
the welding process, the special current, voltage, and
gas flow (in Table 1) were chosen. During the
welding process, the rate between the feeding speed
and welding speed was kept. Then, the acceptable
5 process was derived according to the welding
Weld reinforcement, mm
4 appearance. The ranges of the welding process
parameters are shown in Fig. 8. It could be seen that
3
the maximum welding speed of root welding based
2 on the hot-wire TIG welding could be improved to
1 160 mm/min (the maximum welding speed of
ordinary TIG welding was only 90 mm/min) when
0
300 the current, voltage, and the gas flow were kept. And
also the maximum wire feeding speed of the root
welding could be improved to 2000 mm/min.
There was a linear relationship between the
melting efficiency and the feeding speed. Therefore,
the melting efficiency can be calculated from the
feeding speed as following:
dv
dA%   100% (2)
v0
where v is feeding speed, A is melting efficiency.
The melting efficiency increases approximately
100% (for root welding) and 200% (for filling and
cap welding) respectively. When the welding speed
and the feeding speed are 160 mm/min and 2000
mm/min, the welding appearances are shown in Fig.8
(c). The appearance of the hot-wire TIG welding is
more fine.
this investigation with the ordinary TIG welding, two
kinds of joints were obtained from the two welding
methods. The welding parameters are shown in Table
1. The maximum welding speeds of the two welding
 Fujun Cao et al. / Energy Procedia 144 (2018) 9–15 13
Author name / EnergyProcedia 00 (2018) 000–000 5

methods were employed. The similar macro
morphologies of the joints based on the two welding
methods are shown in Fig. 9.
•℃), m is the weight of the hot wire, the unit weight
of the wire m0=8.9g/mm( Φ 1.2mm), the rang of
temperature △t=220℃, efficiency =1(regardless of
the heat loss), the welding speed v=160mm/min, v´
=90mm/min, the wire speeding v0=2000/min.
The results indicate that the heat input of the
hot-wire TIG welding (Q=791.2585J/mm) is less
than the heat input of the ordinary TIG welding (Q´
=1386.67J/mm).

Fig. 9. Macro morphology of the welding joint: (a)Ordinary TIG

welding joint; (b)Hot-wire TIG welding joint.

The microstructures of the three welding layers

are shown in Fig. 10. The microstructures of the root
layer and filling layer were ferrite and small amount
of pearlite. With regard to the cap layer, the
microstructures were columnar and equiaxial ferrite.
It could be concluded from the Fig. 10 that the
microstructure of the hot-wire TIG welding was finer
than that of the ordinary TIG welding. Finer
microstructure means the more rapid cooling rate.
Moreover, the more rapid cooling rate means the
smaller heat input. The heat input of the hot-wire TIG
welding was greater than the ordinary TIG welding
from the traditional heat input model. When taking
Fig. 10. Microstructure of welding joints: (a)Root layer of Hot-
the heat input of the welding wire, the heat input was
wire TIG; (b) Root layer of Ordinary TIG; (c) Filling layer of Hot-
difficult to be calculated. However, the heat input of wire TIG; (d) Filling layer of Ordinary TIG; (e)Cap layer of Hot-
the hot-wire TIG welding should be still less than the wire TIG; (f) Cap layer of Ordinary TIG.
ordinary one according to the microstructure of the
two welding methods. According to the energy The microhardness of the root welding is
balance method, the heat input per millimeter can shown in Fig.11. The microhardness of the BM(Base
also be calculated as following. Metal) is in the range of 145-150HV, and the
maximum microhardness of the HAZ(Heat Affected
Q  Q1    Q2 (3) Zone) reaches to 190HV. Besides, the WM(Weld
U  I  60 Metal) microhardness of the hot-wire TIG is higher
Q1  (4) than ordinary TIG. Mainly because the WM-grain of
v
the hot-wire TIG is fine so that the fine-grain
Q 2  c  m  t (5) strengthening is obvious. According to the two
v welding joints, the microhardness peak reaches to
m  0  m0 (6) 195HV during the NZ(Normalizing Zone), and the
v
microhardness of the CGHAZ(Coarsening Grain
U 'I '60 Heat Affected zone) is less than the WM，but higher
Q'  (7)
v' than the BM.
Where Q is the heat input of the hot-wire TIG
welding, Q1 is the arc heat, Q2 is the wire heat, Q´ is
the heat input of the ordinary TIG welding, Root
welding voltage U=U´=13V, Root welding current I=
I´=160A, Specific heat capacity c=0.46×103J/(Kg
14 Fujun Cao et al. / Energy Procedia 144 (2018) 9–15
6 Author name / Energy Procedia 00 (2018) 000–000
Fig. 11. Hardness distribution of the backing welding layer.
The discussion about the microhardness
distribution was based on the hot-wire welding joint.
Fig. 12. (a)Microstructure of base metal; (b)Microstructure of heat affected zone;(c)Microstructure of nuclear zone.
The tensile strength of the two joint was
approximately 510 MPa. The fractured joints are
shown in Fig. 13. The fracture was located on the
base metal. Therefore, the hot-wire TIG welding
method has not damaged the mechanical property of
the joint.
Fig. 13. Macro morphologies of the fractured joints.
4. Conclusions
(1) The magnetic bias and the arc phenomenon
of the hot-wire TIG welding were avoided based on
the heat-conduction method. The cost of the
equipment was low. The equipment was easy to be
operated.
The microstructure of the as-received A106 steel was
ferrite and pearlite as shown in Fig. 12 (a). The
coarsening grain heat affected zone (CGHAZ) cooled
to the room temperature after totally austenitizing.
The microstructure was ferrite with a grain size
smaller than the base metal. Therefore, the hardness
of the CGHAZ was lower than the base metal slightly.
The microstructures of the normalizing zone (NZ)
and the In-completely normalizing zone (INZ) were
shown in Fig. 12 (c). It could be seen that the
microstructure of the NZ was finer than that of the
CGHAZ. Therefore, the peak of the hardness was
located in the normalizing zone of the joint.
(2) The closed loop control system between the
heating equipment and wire temperature was
designed. The temperature controlling model about
the temperature of heater and the feeding speed was
investigated. The wire temperature could be set at
220±5°C when the feeding speed ranging from 0 to
3500mm/min.
(3) The welding appearance and welding speed
of the hot-wire TIG welding were improved. The
welding efficiency of the hot-wire welding with a
wire temperature of 220 °C was improved by more
than 100%, as the weak chilling effect of the welding
wire on the welding arc.
(4) The microstructure of the welding metal of
the hot-wire TIG welding was finer than that of the
ordinary TIG welding when the similar welding
appearances were obtained. The hardness of the
welding metal was higher than that of the base metal
slightly. Good mechanical properties have also been
indicated. The fractures of the hot-wire/ordinary TIG
welding joints were all located on the base metal.
Reference
 Fujun Cao et al. / Energy Procedia 144 (2018) 9–15 15
Author name / EnergyProcedia 00 (2018) 000–000 7

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