The Formation Mechanism and Suppression Strategies of Spatter in Pulsed Gas Metal Arc Welding for Titanium Alloy

Zhendan Zheng, Shaojie Wu, Limin Fan, Hao Wu, Fangjie Cheng
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Abstract

The GMAW process for titanium alloy is not commonly applied within the industry due to the occurrence of severe spatter. This research endeavors to elucidate the mechanism underlying spatter formation and explore efficacious strategies to suppress spatter. The experimental results demonstrated the existence of two distinct spatter types: large and small spatter particles. The high- speed images and synchronous electrical signals were utilized for determining the spatter formation mechanism, with force analysis serving to mutually validate the inferences. The large spatter particles originated from the whole transitional molten droplet as it descended within the arc space, while the small spatter particles were formed by the partial transitional molten droplet as it contacted the weld pool. The cathode jet force accounted for the formation of large spatter particles, whereas the electromagnetic force was responsible for the small spatter particles. To suppress spatter, increasing detachment current and decreasing pulsing frequency were employed. Consequently, the spatter rate witnessed a remarkable decrease from 14.00% to 3.33% with a progressive increment in detachment current from 100 A to 300 A, and a corresponding decline from 12.67% to 1.33% upon decrementing the pulsing frequency from 90 Hz to 50 Hz. This research suggests that a judicious increase in the detachment current can effectively decrease the spatter rate while concurrently preserving welding efficiency.
钛合金脉冲气体金属弧焊中飞溅物的形成机理与抑制策略
由于会产生严重的飞溅,钛合金的 GMAW 工艺在行业内并不常用。本研究致力于阐明飞溅形成的机理,并探索抑制飞溅的有效策略。实验结果表明存在两种不同的飞溅类型:大飞溅颗粒和小飞溅颗粒。利用高速图像和同步电信号确定了飞溅形成机制,并通过力分析对推论进行了相互验证。大的飞溅颗粒源于整个过渡熔滴在电弧空间内下降的过程,而小的飞溅颗粒则是由部分过渡熔滴接触焊池时形成的。阴极喷射力是形成大飞溅颗粒的原因,而电磁力则是形成小飞溅颗粒的原因。为了抑制飞溅,采用了增加脱离电流和降低脉冲频率的方法。结果,当脱离电流从 100 安培逐渐增加到 300 安培时,飞溅率从 14.00% 显著下降到 3.33%;当脉冲频率从 90 赫兹降低到 50 赫兹时,飞溅率从 12.67% 相应下降到 1.33%。这项研究表明,明智地增加剥离电流可有效降低飞溅率,同时保持焊接效率。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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