Welding in the World最新文献

An improved DeepLab V3 + : for robust extraction of laser stripes in high-noise environments for automated welding 改进的DeepLab V3 +：用于高噪声环境中自动焊接激光条纹的稳健提取

IF 3.1 4区材料科学

Welding in the World Pub Date : 2026-07-06 DOI: 10.1007/s40194-026-02544-6

Yanjun Xiao, Zijian Han, Weiling Liu, Feng Wan, Yanchun Xiao

{"title":"An improved DeepLab V3 + : for robust extraction of laser stripes in high-noise environments for automated welding","authors":"Yanjun Xiao, Zijian Han, Weiling Liu, Feng Wan, Yanchun Xiao","doi":"10.1007/s40194-026-02544-6","DOIUrl":"10.1007/s40194-026-02544-6","url":null,"abstract":"<div><p>In automated welding, accurate weld seam tracking is essential for improving manufacturing quality and efficiency. Vision-based laser stripe centerline extraction is a key technique for seam tracking, but intense arc light, spatter, and reflections in welding environments often degrade image quality and reduce extraction robustness. To address this problem, this study proposes an improved DeepLab V3 + semantic segmentation model for robust laser stripe extraction in high-noise welding images. MobileNetV3 is adopted as the backbone to improve inference efficiency. A context-anchored attention module is introduced into the encoder to enhance the perception of elongated laser stripe structures and suppress noise responses. In the decoder, DySample dynamic upsampling is used to improve edge and detail reconstruction. In addition, multiscale feature fusion is employed, and a combined Focal Loss and Dice Loss function is used to alleviate foreground–background imbalance. On the held-out test set, the proposed method achieved 94.96% mean intersection over union, 97.96% mean pixel accuracy, 93.93% precision, 95.92% recall, 94.91% F1/Dice score, and an inference speed of 53 frames per second. Compared with selected general semantic segmentation baseline models, the proposed method provides a favorable balance among segmentation accuracy, inference speed, and model size and offers effective preprocessing for downstream laser stripe extraction and weld feature-point localization under the tested high-noise welding conditions.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 8","pages":"3663 - 3676"},"PeriodicalIF":3.1,"publicationDate":"2026-07-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148695553","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Lightweight denoising autoencoder for real-time weld seam tracking on reflective metals 用于反射金属焊缝实时跟踪的轻型降噪自动编码器

IF 3.1 4区材料科学

Welding in the World Pub Date : 2026-07-03 DOI: 10.1007/s40194-026-02538-4

Nurettin Gökhan Adar, Ali Yildiz

{"title":"Lightweight denoising autoencoder for real-time weld seam tracking on reflective metals","authors":"Nurettin Gökhan Adar, Ali Yildiz","doi":"10.1007/s40194-026-02538-4","DOIUrl":"10.1007/s40194-026-02538-4","url":null,"abstract":"<div><p>Weld seam tracking in reflective metal welding environments remains a challenging task due to intense arc glare, spatter, and smoke, which severely degrade image quality. Conventional laser-based vision systems often fail under such conditions, leading to inaccurate seam localization. This study presents a lightweight denoising autoencoder (L-DAE) specifically designed to enhance weld seam visibility while enabling real-time deployment on embedded hardware. The proposed architecture incorporates adaptive spatial and channel attention modules to suppress localized noise patterns while preserving fine-grained laser line features. A dedicated dataset of 38,000 noisy–clean image pairs was collected from a Cartesian robotic welding platform, covering diverse part orientations and reflective galvanized steel surfaces. Experimental evaluations show that the L-DAE achieves 31.8 dB PSNR, 98.2% IoU, and 99.5% F1-score, outperforming baseline CNN and GAN models. The model delivers 30 FPS on an NVIDIA RTX 3060 GPU and maintains ± 0.2 mm tracking accuracy across varying orientations. On the NVIDIA Jetson NX, the network achieves real-time performance with only marginal accuracy degradation, confirming its suitability for industrial deployment where computing resources are limited. These results demonstrate that the proposed L-DAE offers a robust and computationally efficient solution for weld seam tracking in highly reflective environments. Future work will address cross-material generalization and integration with multi-modal sensing for enhanced stability in dynamic manufacturing settings.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 8","pages":"3649 - 3662"},"PeriodicalIF":3.1,"publicationDate":"2026-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148695081","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Numerical simulation of effect for weld surface morphologies in ultra-narrow gap welding on plate tungsten cathode arc characteristics with insulating solid wall constriction 超窄间隙焊接中焊缝表面形貌对绝缘固壁收缩钨极板电弧特性影响的数值模拟

IF 3.1 4区材料科学

Welding in the World Pub Date : 2026-06-27 DOI: 10.1007/s40194-026-02536-6

Li Yuanbo, Li Yuwei

{"title":"Numerical simulation of effect for weld surface morphologies in ultra-narrow gap welding on plate tungsten cathode arc characteristics with insulating solid wall constriction","authors":"Li Yuanbo, Li Yuwei","doi":"10.1007/s40194-026-02536-6","DOIUrl":"10.1007/s40194-026-02536-6","url":null,"abstract":"<div><p>Three typical weld surface morphologies will be formed during the process of ultra-narrow gap welding with plate tungsten cathode arc constricted by insulating solid wall, which are symmetrical concave type, symmetrical convex type, and unilateral concave type. Based on the fluid dynamics equations and Maxwell’s equations, a three-dimensional mathematical model of plate tungsten cathode arc constricted by insulating solid wall under different weld surface morphologies in ultra-narrow gap is established. Then the arc current density field, Lorentz force field, flow field, and temperature field are obtained by iterative solution of the governing equations. The results show that the morphology of the weld surface will change the arc discharge gap in the ultra-narrow gap, so that the diversion effect of the arc to the groove bottom and corner will change. The stronger the diversion effect of the arc to the groove bottom and corner is, the more obvious the expansion of the current density field, Lorentz force field and temperature field at the groove bottom and corner is, while the arc jet was weakened. On the contrary, the weakening of the diversion effect of the arc to the groove bottom and corner will cause the current density field, Lorentz force field and temperature field to shrink. And then, the arc jet will be strengthened. The diversion effect of three weld surface morphologies from strong to weak is symmetrical concave type, unilateral concave type, and symmetrical convex type.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 8","pages":"3629 - 3647"},"PeriodicalIF":3.1,"publicationDate":"2026-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148695269","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Physical characteristics of high-frequency pulsed twin-tungsten inert gas arc 高频脉冲双钨惰性气体电弧的物理特性

IF 3.1 4区材料科学

Welding in the World Pub Date : 2026-06-25 DOI: 10.1007/s40194-026-02523-x

Xinlong Zhao, Maoai Chen, Jinqiang Gao, Chuanbao Jia, Chuansong Wu

{"title":"Physical characteristics of high-frequency pulsed twin-tungsten inert gas arc","authors":"Xinlong Zhao, Maoai Chen, Jinqiang Gao, Chuanbao Jia, Chuansong Wu","doi":"10.1007/s40194-026-02523-x","DOIUrl":"10.1007/s40194-026-02523-x","url":null,"abstract":"<div><p>This study systematically investigates the physical characteristics of high-frequency pulsed twin-tungsten inert gas (HFPT-TIG) arc and the underlying influencing mechanisms. High-speed imaging, arc force measurement, and electrical signal acquisition were carried out to examine the effects of tungsten electrode spacing, arc length, and welding current, as well as high-frequency pulse frequency and amplitude on arc morphology, arc force distribution, and static arc characteristics. The results indicate that, at small electrode spacing, the HFPT-TIG arc exhibits a stable bell-shaped morphology. The superposition of high-frequency pulsed current significantly enhances arc constriction, which is more pronounced when observed from the front camera direction, thereby increasing arc stiffness and effectively suppressing arc lagging under high welding speeds. Compared with conventional TIG and twin-tungsten TIG (T-TIG) arc, HFPT-TIG further enhances penetration capability and arc energy concentration on the basis of the already good humping suppression ability of T-TIG. Moreover, the static characteristic curve of HFPT-TIG arc displays a typical U-shaped profile, with arc voltage values lying between those of TIG and T-TIG arcs. These findings demonstrate that HFPT-TIG welding offers distinct advantages in achieving high penetration capability, high humping resistance, and enhanced process stability, providing a solid physical basis for high-efficiency and high-quality welding of thin-sheet materials.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 8","pages":"3595 - 3618"},"PeriodicalIF":3.1,"publicationDate":"2026-06-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148695247","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Physics-model-driven method for weld seam point cloud data generation and feature extraction 基于物理模型驱动的焊缝点云数据生成与特征提取方法

IF 3.1 4区材料科学

Welding in the World Pub Date : 2026-06-20 DOI: 10.1007/s40194-026-02521-z

Tie Zhang, Xinjie Wang, Yanbiao Zou

{"title":"Physics-model-driven method for weld seam point cloud data generation and feature extraction","authors":"Tie Zhang, Xinjie Wang, Yanbiao Zou","doi":"10.1007/s40194-026-02521-z","DOIUrl":"10.1007/s40194-026-02521-z","url":null,"abstract":"<div><p>Accurate localization of weld seams from workpiece surface point clouds using segmentation networks often faces challenges due to the difficulty in preparing adequate training datasets. To mitigate this limitation, a physics-model-driven approach for generating weld seam point clouds that replicate the geometric and noise characteristics of laser structured-light measurement is proposed. This approach utilizes weld bevel geometry and spatial trajectories of feature points as prior knowledge. It employs NURBS curve fitting to uniformly discretize feature point trajectories, while incorporating Gaussian noise based on laser vision imaging principles to generate high-fidelity, automatically annotatable weld point cloud datasets. Building upon this foundation, a feature point extraction method integrating local oriented bounding boxes (LOBB) with concavity-convexity analysis is proposed. This enables accurate identification of critical edge points on welds while effectively mitigating misidentification caused by surface protrusions on lap welds. Experimental results demonstrate that the model’s performance degradation in real-world scenarios does not exceed 14%, with average path error for three weld types remaining below 0.2 mm. This validates the method’s effectiveness and engineering feasibility.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 8","pages":"3567 - 3593"},"PeriodicalIF":3.1,"publicationDate":"2026-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148695527","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Fatigue life improvement of lap-fillet-welded UHSS by controlling the weld metal shape and welding wire Cr content 控制焊缝金属形状和焊丝Cr含量提高搭接角焊超高压钢的疲劳寿命

IF 3.1 4区材料科学

Welding in the World Pub Date : 2026-06-20 DOI: 10.1007/s40194-026-02530-y

Kaname Toda, Reiichi Suzuki, Yusuke Hoshino, Kazuhiro Ito, Seong Min Hong, Habib Hamed Zargari, Shumpei Ozawa

{"title":"Fatigue life improvement of lap-fillet-welded UHSS by controlling the weld metal shape and welding wire Cr content","authors":"Kaname Toda, Reiichi Suzuki, Yusuke Hoshino, Kazuhiro Ito, Seong Min Hong, Habib Hamed Zargari, Shumpei Ozawa","doi":"10.1007/s40194-026-02530-y","DOIUrl":"10.1007/s40194-026-02530-y","url":null,"abstract":"<div><p>The use of thin ultra-high tensile strength steel (UHSS) sheets for automobiles to reduce their weight is an effective method to decrease greenhouse gas emissions, and they are adopted to chassis parts where the sufficient fatigue life of lap-fillet arc-welded joints is required. Generally, the fatigue life of welded joints does not necessarily increase with steel sheet strength, since fatigue behavior is primarily affected by weld geometry and local stress concentration at weld toe. In this study, the effect of Cr contents in welding wires on the shape and hardness of weld metals and fatigue life was investigated by using lap-fillet gas metal arc welding (GMAW) joints of 1.2-GPa cold-rolled UHSS sheets. Four types of solid wires for GMAW with wire Cr contents from 1 to 15% were applied. The fatigue life of joints welded with higher-Cr wires tended to be longer than that of 1% Cr wire. Weld metal hardness also increased with increasing wire Cr content. The shape of the weld metal varied depending on wire Cr content and welding condition. In particular, high-Cr welds with flatter weld metal shapes, characterized by lower height, greater width, and smaller toe angles, showed improved fatigue life. This improvement was attributed to reduced stress concentration at the weld toe and increased weld metal hardness. For forming flat weld metal, it was effective to change the wire tip aiming position from the root to the bottom sheet side. Consequently, controlling both the shape and hardness of the weld metal by selecting welding wire composition and wire aiming position is a practical method to improve fatigue life.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 8","pages":"3619 - 3628"},"PeriodicalIF":3.1,"publicationDate":"2026-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148695529","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

High-speed monitoring and control of forming defects in coarse-wire MAG welding based on multi-frame spatio-temporal neural networks 基于多帧时空神经网络的粗丝MAG焊接成形缺陷高速监测与控制

IF 3.1 4区材料科学

Welding in the World Pub Date : 2026-06-15 DOI: 10.1007/s40194-026-02471-6

Hao Yuan, Shibo Wei, Jiamin Yi, Chaoke Li, Ziran Wang, Zekun Yang, Zhanli Yang

{"title":"High-speed monitoring and control of forming defects in coarse-wire MAG welding based on multi-frame spatio-temporal neural networks","authors":"Hao Yuan, Shibo Wei, Jiamin Yi, Chaoke Li, Ziran Wang, Zekun Yang, Zhanli Yang","doi":"10.1007/s40194-026-02471-6","DOIUrl":"10.1007/s40194-026-02471-6","url":null,"abstract":"<div><p>To mitigate undercut and humping defects induced by arc instability during high-speed coarse-wire gas metal arc welding (MAG), this study proposes a lightweight multi-frame spatio-temporal convolutional network for adaptive defect control. The network takes consecutive multi-frame images as input and employs an ordered cross-entropy loss with reward–penalty weighting to improve defect recognition accuracy. Model lightweighting is achieved via spatio-temporal decomposed convolutions, a depthwise-separable bottleneck, and global adaptive pooling, resulting in a 61% reduction in parameter count. Experiments under different groove configurations and welding angles show that the overall performance is optimal with a five-frame input, achieving an accuracy of 96.1%. For the four welding states, the model attains a macro-averaged F1 score of 0.8315 and an area under the curve (AUC) of 0.965, with a recall of 0.82 for critical defects (undercut/humping), and an average network forward inference latency of 1.5 ms. Furthermore, in proof-of-concept closed-loop tests, the controller exhibits stable behavior and improved weld bead formation, indicating real-time feasibility and deployment potential on the current prototype. This work provides practical guidance for the design of future adaptive welding systems targeting high-speed coarse-wire MAG processes.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 8","pages":"3533 - 3551"},"PeriodicalIF":3.1,"publicationDate":"2026-06-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148695524","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Comparative thermal and computational analysis of the WAAM process using FEM and FDM models with experimental validation 采用有限元和FDM模型对WAAM过程进行了热分析和计算分析，并进行了实验验证

IF 3.1 4区材料科学

Welding in the World Pub Date : 2026-06-06 DOI: 10.1007/s40194-026-02505-z

Xabier Sandua, Juan Sustacha, Miguel Arizmendi, Fernando Veiga, Alfredo Suarez

{"title":"Comparative thermal and computational analysis of the WAAM process using FEM and FDM models with experimental validation","authors":"Xabier Sandua, Juan Sustacha, Miguel Arizmendi, Fernando Veiga, Alfredo Suarez","doi":"10.1007/s40194-026-02505-z","DOIUrl":"10.1007/s40194-026-02505-z","url":null,"abstract":"<div><p>This study investigates the thermal behavior of a WAAM-deposited single bead through two different numerical modelling strategies: Finite Element Method (FEM) and Finite Difference Method (FDM). There is still a lack of direct comparative studies between different discretization strategies applied under identical experimental conditions. In particular, the trade-off between prediction accuracy and computational efficiency in FEM and FDM thermal models has not been sufficiently quantified for WAAM applications. Both approaches integrate a double double-ellipsoid heat source model to better capture the melt pool geometry, resulting in high agreement with experimental profiles and fusion boundaries. The parameters of the double double-ellipsoid heat source were defined from melt pool boundaries extracted from experimental bead cross-sections using an image-processing procedure. In addition, a comparative analysis of modelling accuracy and computational cost is carried out, showing that while both methods yield reliable predictions and comparable accuracy in the estimation of the melt pool geometry and the heat-affected zone (HAZ), the FDM approach reduces the simulation time by approximately a factor of 30 compared with the FEM model, without compromising prediction quality. These findings highlight the potential of simplified thermal models for industrial implementation, offering a practical balance between precision and efficiency in WAAM process simulation.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 8","pages":"3553 - 3566"},"PeriodicalIF":3.1,"publicationDate":"2026-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-026-02505-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148695194","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Deep learning-based image analysis to study arc characteristics and metal transfer in GMAW 基于深度学习的GMAW电弧特性与金属转移图像分析

IF 3.1 4区材料科学

Welding in the World Pub Date : 2026-05-19 DOI: 10.1007/s40194-026-02465-4

J. Eduardo Alvarez-Rocha, Lucas Taipe, Patricio F. Mendez

{"title":"Deep learning-based image analysis to study arc characteristics and metal transfer in GMAW","authors":"J. Eduardo Alvarez-Rocha, Lucas Taipe, Patricio F. Mendez","doi":"10.1007/s40194-026-02465-4","DOIUrl":"10.1007/s40194-026-02465-4","url":null,"abstract":"<div><p>This paper presents a novel application of deep learning to quantify arc region characteristics and metal transfer behavior in gas metal arc welding using high-speed videography and synchronized electrical signals. The motivation for this work is the need for scalable and objective methods to analyze features such as arc length, droplet size, and droplet transfer frequency. A U-Net model was modified to achieve multi-class segmentation and trained to process approximately 15,000 frames per video across globular and spray transfer modes using ER4043 aluminum wire. The model segments four distinct classes within the arc region: internal arc, external arc, molten consumable, and droplet. During training, the model achieved an average intersection over union of 0.912 with a low loss of <span>(3.2times 10^{-3})</span>. The model achieved errors below 10% across all arc-length definitions and 6.6% for droplet transfer frequency when compared with manual measurements. The results show that the projected droplet area increases with voltage and decreases with current, consistent with observed frequency trends. This method provides an automated alternative to manual image analysis for the conditions studied and establishes a foundation for future welding arc research, waveform development, and adaptive control. Extension to other materials, transfer modes, and broader welding conditions will require further validation.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 8","pages":"3505 - 3518"},"PeriodicalIF":3.1,"publicationDate":"2026-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148695437","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Flux column effects on metal transfer mechanism in a rutile-type FCAW: insights from comparisons with MCAW and GMAW 金红石型FCAW中通量柱对金属传递机制的影响：与MCAW和GMAW比较的见解

IF 3.1 4区材料科学

Welding in the World Pub Date : 2026-05-12 DOI: 10.1007/s40194-026-02482-3

Dang Khoi Le, Shinichi Tashiro, Kieu Anh Duong Nguyen, Quang Ngoc Trinh, Tetsuo Suga, Naoki Sawamura, Kazuhiro Fukuda, Shuji Sasakura, Patricio Fernando Mendez, Anthony B. Murphy, Van Hanh Bui, Manabu Tanaka

{"title":"Flux column effects on metal transfer mechanism in a rutile-type FCAW: insights from comparisons with MCAW and GMAW","authors":"Dang Khoi Le, Shinichi Tashiro, Kieu Anh Duong Nguyen, Quang Ngoc Trinh, Tetsuo Suga, Naoki Sawamura, Kazuhiro Fukuda, Shuji Sasakura, Patricio Fernando Mendez, Anthony B. Murphy, Van Hanh Bui, Manabu Tanaka","doi":"10.1007/s40194-026-02482-3","DOIUrl":"10.1007/s40194-026-02482-3","url":null,"abstract":"<div><p>This study investigates the role of the flux column in the metal transfer process of Flux-Cored Arc Welding (FCAW). Three rutile-type wires with varying flux ratios were compared with metal-cored and solid wires under Ar-CO<sub>2</sub> shielding at 220—280 A. Transfer frequencies increased with current for all wires. At 280 A, FCAW and Metal‑Cored Arc Welding (MCAW) showed higher frequencies (142.9 and 240.5 Hz) than Gas Metal Arc Welding (GMAW) (69.8 Hz). At 220 A, FCAW and MCAW showed similar frequencies (82.1 and 71.8 Hz) attributed to long flux or metal columns (un-melted metal core), which prevented neck formation by the Lorentz force. In the 250—280 A range, the MCAW frequency increased significantly, reaching 168% of FCAW, likely because melting shortened the metal column, allowing the Lorentz force to act more effectively on droplets. Increasing the flux ratio from 12 to 20% slightly reduced flux column length and increased frequency from 131.4 to 162.8 Hz at 280 A. The ratio of Wire Feed Speed (WFS) to transfer frequency was proportional to droplet diameter. WFS increased linearly with current for all wires. Droplet diameters decreased sharply for MCAW (1.60 to 1.20 mm) and GMAW (2.43 to 1.72 mm), but only slightly for FCAW (1.60 to 1.45 mm) in the 220—280 A range. Through comparisons of frequencies and WFSs, the former was a dominant factor for controlling droplet diameters. Consequently, the results suggest that the flux column length governs the droplet size in FCAW.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 8","pages":"3861 - 3873"},"PeriodicalIF":3.1,"publicationDate":"2026-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-026-02482-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148695558","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0