University of Kentucky Research Foundation

Liguo E

YuMing Zhang

Radovan Kovacevic

An improved method of gas metal arc welding (GMAW) utilizing relatively low current levels. The method includes providing a variable current to form and detach a droplet from a consumable wire electrode. During the welding process, the current is sufficient to produce a droplet at the end of a consumable electrode wire, but not to independently detach the droplet. After the droplet reaches a desired diameter, the current is lowered to induce an oscillation in the droplet. At a selected oscillation of the droplet, the current is increased. The combination of the momentum created by the oscillation of the droplet and the electromagnetic force caused by the increased current serves to detach the droplet from the electrode wire.

Method of gas metal arc welding

An improved method of gas metal arc welding (GMAW) is disclosed. The method includes utilizing a pulsed current having a variable waveform to ensure the detachment of one-droplet-per-pulse of current. During the welding process, the current is sufficient to produce a droplet at the end of a consumable electrode wire. After the droplet reaches a desired size, the current is lowered to induce an oscillation in the droplet. The current is then increased which, in combination with the momentum created by the oscillation, effects droplet detachment. The oscillation may be monitored by observing the arc voltage to determine a preferred detachment instant. A computer implemented method allows for the adaptive control of the current waveform to accommodate for anticipatable variations in the welding conditions, while maintaining ODPP transfer and a constant pulse period. An accompanying system is disclosed for implementing the method of adaptive welding.

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Lexington, KY, United States of America

Liguo E