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WELDING RESEARCH
SUPPLEMENT TO THE WELDING JOURNAL, MAY 2017
Sponsored by the American Welding Society and the Welding Research Council
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1A 2A 3A 1A 2A 3A
3B
1B 2B 1B 2B 3B
Fig. 3 — Symmetrical oscillation at the center of the pool under Fig. 4 — Symmetrical oscillation at the center of the pool under
partial penetration. complete joint penetration.
designed for exploring oscillation be- dynamic variation in the weld pool face was concave, whereas the center
havior and partial penetration. Experi- surface such that the pool oscillation of the weld pool expanded toward the
ment 3 was designed for exploring behavior could be clearly observed. Re- outside [Fig. 3(2b)], correspondingly,
forced oscillation. Experiments 4 and sults of the experiment showed three and the shape of the weld pool oscilla-
6 were designed for complete joint pool oscillation modes at different tion surface was convex.
penetration and oscillation behavior. depths of penetration. Figure 3(1b and 2b) shows that the
Experiments 5 and 7 were designed weld pool oscillation in the partial pene-
for critical penetration and oscillation Symmetrical Oscillation under Partial tration is symmetrical about the center
behavior. The other experiments were Penetration of the weld pool. As was presented in
designed for analyzing pool oscillation Refs. 18 and 20, the oscillation model
behavior or amplitude issues. Figure 3(1b) and (2b) are the con- can be described with the first harmonic
secutive reflected laser dot-matrix im- mode of the Bessel function.
Experimental Results and ages of the oscillating weld pool at par- The arc pressure is known to be
tial penetration, such as those in Ex- caused by a magnetic pressure differen-
Discussion periments 2 and 5 in Table 1. The pixel tial along the length of the arc, which
distance of adjacent laser dots in the accelerates the arc plasma and entrains
Pool Oscillation Mode weld pool center in Fig. 3(1b) is rela- the gas toward the workpiece to form a
tively large, while in Fig. 3(2b) it is dynamic jet pressure (Refs. 8, 29). It in-
The oscillating weld pool was im- much smaller. This concurs with the creases with the square of the current
aged/captured at 1000 f/s by the high- characteristic principles discussed in and decreases from electrode to work-
speed camera during welding. Both the the section titled “characteristics for piece as the arc radius increases. Thus,
convexity and concavity of the weld pool oscillation.” The center of the the arc jet pressure derived from the
pool surface under the pulse current weld pool shrank toward the inside peak current is much greater than that
were observed. The variation in the re- [Fig. 3(1b)] and, correspondingly, the derived from the base current.
flected laser dot matrix presented the shape of the weld pool oscillation sur- When the welding current is
No Peak Current Base Current Peak Time Base Time Pulse Frequency Captured Rate Target of Study
Ip/A Ib/A Tp/ms Tb/ms f/Hz f/s
1 60 60 — — — 1000 DC oscillation
2 60 20 20 20 25.0 1000 Partial / behavior
3 80 20 20 3 43.5 1000 Forced oscillation
4 80 20 20 5 40.0 1000 Complete / behavior
5 80 20 20 20 25.0 1000 Mode / behavior
6 100 20 20 10 33.33 1000 Complete / behavior
7 100 20 20 20 25.0 1000 Critical / behavior
8 120 20 20 5 40.0 1000 Oscillation behavior
9 140 20 20 5 40.0 1000 Oscillation behavior
10 160 20 20 5 40.0 1000 Oscillation behavior
* Partial – partial joint penetration; complete — complete joint penetration; critical – critical penetration; mode – partial and critical penetration; behavior –
oscillation behavior.
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A B
Fig. 7 — Pool oscillation process under greater partial penetration (Ip = 80 A, Ib = 20 A, f = 25 Hz, Tb = 20 ms): A — Amplitude variation of
pool oscillation; B — some typical pool oscillation images. (Welding base time from 4608 to 4628 ms.)
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Discussion
The authors have studied in detail
the oscillation modes and dynamic be-
haviors. However, the studies were
done under pulsed current with mod-
erate frequency. To gain a broader and
more complete view, the authors
wished to briefly study the oscillations
under extreme frequencies by using di-
rect current (DC) as the extreme for
low frequency and pulsing current
with high frequency.
A
Pool Dynamic Behavior under Direct
Current GTAW
WELDING RESEARCH
Conclusion
Pool oscillation behavior has been
characterized by and analyzed from
the reflection laser dot-matrix pattern
from the oscillating weld pool surface.
From reflection laser dot-matrix A B C D
pattern-based analyses, the following
conclusions can be drawn for the pool Fig. 13 — Forced pool oscillation under highfrequency pulse current (Ip = 80 A, Ib = 20 A, f
oscillation in GTAW-P: = 43.5 Hz, Tb = 3 ms).
1) Pool oscillation dynamic behav-
iors can be clearly observed and easily duced to the base level but its continu- References
measured according to the reflected ation to finish a complete cycle re-
images derived from the laser dot- quires the base current period be suffi- 1. Zhang, Z. Z., and Wu, C. S. 2015. Ef-
matrix sensing method. ciently long in comparison with the fect of fluid flow in the weld pool on the
2) The dynamic evolution process period of natural frequency. A relative- numerical simulation accuracy of the ther-
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the innovative three-dimensional weld 6) Oscillations with smaller ampli- Zhang, X. Y. 2014. Plasma arc welding:
pool surface sensing method. tude still exist in the weld pool during Process, sensing, control and modeling.
Journal of Manufacturing Processes 16:
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lation gradually increases as the peak The financial support from the Chi- Manufacturing Processes 16: 109–122.
current increases. This is because the na Scholarship Council is greatly ap- 5. Bahrami, A., Aidun, D. K., and Valen-
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WELDING RESEARCH
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K. E. ZHANG (zhangke@sjtu.edu.cn), SHAOJIE WU, YUMING ZHANG (yuming.zhang@uky.edu), and JINSONG CHEN are with the Insti
tute for Sustainable Manufacturing, University of Kentucky, Lexington, Ky. K. E. ZHANG is also with the Welding and Laser Processing In
stite, Shanghai Jiaotong University, Shanghai, China.