Proposal and Analysis of Device to Optimization of Drop Detachment in MIG/MAG Welding

Abstract

Several forces act in MIG/MAG welding during the transmission of the molten drop in the end of the wire electrode to the weld pool, which vary according to the transfer mode adopted. In the globular mode, the droplet detachment occurs when its weight overcomes the surface tension forces, thus producing larger droplets causing further instability during the transfer. In spray mode, the high current values intensify the action of Lorentz force. This magnetic force provides the detachment of the droplet even in small dimensions, resulting in increased stability. However, this transfer mode is characterized by a large power supply on, which prevents the union of thin or out of position sheets. This work analyzes the feasibility of using an external magnetic force to assist the drop detachment and propose a device for this purpose. The aim is to obtain a similar transfer mode to the spray, but in lower welding current values without the need of electronic sources. Thus, it is expected to achieve greater stability in the process combined to a smaller amount of heat delivered to the workpiece. Nevertheless, the results show the technological impossibility for the use of the proposed device, due to the need for extremely high current levels (around 100.000A) to sensitize the drop at the electrode tip.

Key-words:
Metal transfer; Electromagnetic induction; Lorentz force; MIG/MAG