Advanced Gas Tungsten Arc Weld Surfacing Current Status and Application

Egerland, Stephan; Zimmer, Johannes; Brunmaier, Roland; Nussbaumer, Roland; Posch, Gerhard; Rutzinger, Bernd

doi:10.1590/0104-9224/SI2003.05

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Technical Papers • Soldag. insp. 20 (3) • Sept 2015 • https://doi.org/10.1590/0104-9224/SI2003.05 copy

Advanced Gas Tungsten Arc Weld Surfacing Current Status and Application

Revestimento com GTAW Avançado: Estado da Arte e Aplicações

Authorship SCIMAGO INSTITUTIONS RANKINGS

Abstract

Gas Shielded Tungsten Arc Welding (GTAW) – a process well-known providing highest quality weld results joined though by lower performance. Gas Metal Arc Welding (GMAW) is frequently chosen to increase productivity along with broadly accepted quality. Those industry segments, especially required to produce high quality corrosion resistant weld surfacing e.g. applying nickel base filler materials, are regularly in consistent demand to comply with "zero defect" criteria. In this conjunction weld performance limitations are overcome employing advanced 'hot-wire' GTAW systems. This paper, from a Welding Automation perspective, describes the technology of such devices and deals with the current status is this field – namely the application of dual-cathode hot-wire electrode GTAW cladding; considerably broadening achievable limits.

Keywords:
GTA weld cladding; Single-cathode GTAW; Hot-wire welding; Dual-cathode GTAW

N	Shield gas nozzle	R	Feed rolls
E	Tungsten electrode	S	GTAW power supply (CC mode)
W	Wire reel	T	Contact tube
H	Hot-wire power supply (CV mode)	10	Filler wire
M	Wire feed motor	11-14	Welding leads

Single-cathode twin-hot-wire		Single-cathode twin-hot-wire		Dual-cathode single-hot-wire
Pulse current $I_{p} [A]$	320	Pulse current $I_{p} [A]$	350	Weld current ( $I$ ) [A]	450 ^* * Note that these data represent total values; i.e. require division by 2.
Background current $I_{b} [A]$	280	Background current $I_{b} [A]$	300	Background current $I_{b} [A]$	-
Mean voltage (U) [V]	13.5	Mean voltage (U) [V]	14.2	Mean voltage (U) [V]	12.1
Wire feed rate mmin^–1	1.6 ^* * Note that these data represent total values; i.e. require division by 2.	Wire feed rate mmin^–1	2.6 ^* * Note that these data represent total values; i.e. require division by 2.	Wire feed rate mmin^–1	7.6
Travel speed [cmmin^–1]	32	Travel speed [cmmin^–1]	50	Travel speed [cmmin^–1]	80
Pulse time ( $t_{p})$ [ms]	200	Pulse time ( $t_{p})$ [ms]	150	Pulse time ( $t_{p})$ [ms]	-
Background time ( $t_{b})$ [ms]	200	Background time ( $t_{b})$ [ms]	150	Background time ( $t_{b})$ [ms]	-
Frequency [Hz]	2.5	Frequency [Hz]	3.3	Frequency [Hz]	-
Hot wire current $I_{h}$ [A]	70	Hot wire current $I_{h}$ [A]	70	Hot wire current $I_{h}$ [A]	190

DC constant		DC pulsed
Weld current ( $I$ ) [A]	370	Pulse current ( $I_{p}$ ) [A]	430
Background current ( $I_{b}) [A]$	-	Background current ( $I_{b}) [A]$	370
Mean voltage ( $U$ ) [V]	10.4	Mean voltage ( $U$ ) [V]	11.0
Wire feed rate [mmin^-1)	4.8	Wire feed rate [mmin^-1)	5.0
Weld travel speed [cmmin^-1]	120	Weld travel speed [cmmin^-1]	120
Pulse time ( $t_{p})$ [ms]	-	Pulse time ( $t_{p})$ [ms]	70
Background time ( $t_{b})$ [ms]	-	Background time ( $t_{b})$ [ms]	70
Frequency [Hz]	-	Frequency [Hz]	7.1
Hot wire current $I_{h}$ [A]	240	Hot wire current $I_{h}$ [A]	250

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[1] E-mail: egerland.stephan@fronius.com (SE)