A multiphysics computational model has been developed for the conventional Gas Metal Arc Welding (GMAW) joining process and used to analyze butt-welding of MIL A46100, a prototypical high-hardness armor martensitic steel. The model consists of five distinct modules, each covering a specific aspect of the GMAW process, i.e., (a) dynamics of welding-gun behavior; (b) heat transfer from the electr...

For many years, the welding community has assumed that the detachment events within Gas Metal Arc Welding (GMAW) process are stochastically driven. With this in mind, we set out to better understand these mechanisms and what might drive the detachment events. Through the investigation of 6061-Aluminum GMAW, a number of new insights into globular, and spray transfer modes have been found. By usi...

Laser-enhanced gas metal arc welding (GMAW) is an innovative process recently proposed and developed at the University of Kentucky (Refs. 1–3), shown in Fig. 1. It adds a relatively low-power laser to conventional GMAW, and the objective is to provide an auxiliary force to help detach the droplet at a desired diameter with a desired welding current. In laserenhanced GMAW, the droplet size is a ...

Controlled metal transfer in gas metal arc welding (GMAW) implies controllable weld quality. To understand, analyse and control the metal transfer process, the droplet should be monitored and tracked. To process the metal transfer images in double-electrode GMAW (DE-GMAW), a novel modification of GMAW, a brightness-based algorithm is proposed to locate the droplet and compute the droplet size a...

Double-Electrode Gas Metal Arc Welding (DE-GMAW) is a novel welding process recently developed to increase welding productivity while maintaining the base metal heat input at a desired low level. In this paper, the DE-GMAW process was improved by replacing its non-consumable tungsten electrode with a consumable welding wire electrode resulting in a new process called consumable DE-GMAW. To unde...

Gas metal arc welding (GMAW) is the most widely used process for metal joining because of its high productivity and good quality, but analysis shows that the fundamental characteristic restricts conventional GMAW from further increasing the welding productivity. A novel GMAW process, refereed to as double-electrode GMAW or DE-GMAW, thus has been developed to make it possible to increase the mel...

Gas Metal Arc Welding (GMAW) processes is an important joining process widely used in metal fabrication industries. This paper addresses modeling and optimization of this technique using a set of experimental data and regression analysis. The set of experimental data has been used to assess the influence of GMAW process parameters in weld bead geometry. The process variables considered here inc...

To provide quantitative information to choose the best welding processes for minimizing workplace emissions, nine gas metal arc welding (GMAW) processes for mild steel were assessed for fume generation rates, normalized fume generation rates (milligram fume per gram of electrode consumed), and normalized generation rates for elemental manganese, nickel, and iron. Shielded metal arc welding (SMA...

In this paper, stability and internal dynamics for a gas metal arc welding (GMAW) process will be studied. GMAW process is considered as a nonlinear MIMO system and input-output feedback linearization method will be applied for control purposes. Internal dynamics is the unobservable part of the system dynamics; its stability analysis is a vital step in the investigation of the system stability ...

Installation of new pipelines is predicted to grow at a rapid rate over the next twenty years, due in part to the increase use worldwide of combined cycle power generation plant using natural gas a fuel. The need to construct large diameter pipelines over long distances has led to an increased demand to improve the productivity of pipeline girth welding. Many novel techniques have been tried in...