Measurements of deposition rate and droplet temperature in GMAW of aluminum alloys

Abstract This article explores the reason behind higher deposition rate in Mg-containing aluminum alloys gas metal arc welding (GMAW). Experiments performed on ER1100 (Mg-free alloy) and ER5183 (high Mg alloys) measured current, wire feed speed, droplet temperature. A non-linear analysis of Joule heating at electrode extension an power needed to heat consumable temperature were performed. Analysis revealed that is two orders magnitude smaller than what was necessary for speed. The measurements done first time both consumables under identical conditions, which had a lower by almost 350 K.