Short-circuit Transition Control Technology for CO2 Gas Shielded Welding: Research Status and Prospect
CHEN Tao1,2, ZHAI Peizhuo1,2, GUO Peipei2
1 College of Materials Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing 210016; 2 Kunshan Huaheng Welding Equipment Corporation, Suzhou 215300
Abstract: The features of low cost and high productivity enable the widespread application of CO2 gas shielded welding in manufacturing industry. With the increasing demand for energy saving and emission reduction in the manufacturing industry and the promotion of the concept of lightweight automobile, the requirements of thin plate welding in manufacturing are continuously raising, which cause the traditional welding method can hardly meet the new requirements. Compared with the conventional welding approaches (traditional tungsten argon arc welding, argon-arc welding, laser welding, etc.), CO2 short-circuit transition welding is superior due to its high thermal stability, low heat input, low penetration depth, etc. Yet, the large welding spatter and poor weld formation have blocked its promotion and wide application. The CO2 short-circuit transition welding process is a complex nonlinear time-varying system composed of the arcing phase and the short-circuit phase. The droplet transfer process plays a dominant role in affecting the stability of the welding process and the quality of weld molding. In the arcing stage, the droplets grow under the combined action of electromagnetic contraction force, surface tension, plasma flow force, metal evaporation reaction force, and are short-circuited with the molten pool to form a stable liquid bridge. In the short-circuit phase, as a result of the action of surface tension, electromagnetic contraction force and viscous force, the liquid bridge necks down and finally breaks. The size of droplets and oscillating characteristics in arcing phase, the oscillating characteristics of the molten pool and peak current in the short-circuit phase all profoundly impact the stability of the droplet transition. The research on the spatter generation mechanism of short-circuit transition welding shows that the primary factors causing the instability and splashing in the welding process lie in the redox reaction of the molten droplet pool, the instantaneous short circuit generated in the early stage of short circuit and the liquid bridge electrical explosion at the end of short circuit. Great efforts have been put into the research and exploration on the CO2 short-circuit transition welding droplet transfer process and its control technology. Specifically speaking, the research work can be divided into four aspects, including optimizing the composition of welding materials, modeling and controlling droplets transfer based on output electrical signals of welding power, controlling droplet transfer based on vision sensing technology and CO2 short-circuit transition welding technology based on magnetron technology. The promotion of active welding wire and medicinal welding wire can effectively reduce welding spatter. Wave control technology and CMT technology achieve excellent welding effect under small welding current parameters. Magnetron welding technology exhibits notable advantage in solving welding spatter and forming problems under medium and small current parameters. This paper summarizes the research status of the short-circuit transition control technology for CO2 gas shielded welding both at home and abroad from four aspects: welding wire, power supply, external magnetic field form and technology. Firstly, the spatter generation mechanism of short-circuit transition in CO2 welding is analyzed. Then, several typical principles, characteristics as well as limitations of short-circuit transition control technology for CO2 gas shielded welding are introduced in detail. Besides, the characteristics of diverse short-circuit transition control techniques are analyzed. Finally, the existing problems and corresponding solutions in the current process of research and application of the short-circuit transition control technology are elaborated, and the developing trend in this field are also put forward.
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2019, Vol. 33 
