New Method for Improving the Productivity of Gas Metal Arc Welding and Flux Cored Arc Welding

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This proposal will investigate an innovative approach to make the arc amperage less dependent on wire feed speed plus a unique dual shield torch design which has application to gas metal arc welding and flux cored arc welding. The innovative approach is to use two power sources on one weld wire, one for preheating the wire and the other for providing the welding arc. The significance of this approach is that the weld deposition rate will be less dependent on the arc current as a result of the wire preheating by the second power source. The second part of the innovative approach is to use dual flow gas shielding of the arc area, instead of the conventional one shielding gas. This permits different gas types to be directed to the appropriate region to be most effective. The research plan is to construct the experimental equipment and investigate how much the heat input, deposition rate and travel speed can be varied while still maintaining good weld characteristics. Carbon steel solid and tubular wire will be studied. This Phase I will confirm the feasibility of this approach and determine the operational envelop of the process parameters for carbon steel welding. A follow-on Phase II is planned to investigate the effect of this process on the material properties and expand the studies to other material types, such as low alloy steel, stainless steel and aluminum. If successful, plans are to pursue funds to commercialize this approach. This innovative research, if successful, has the potential to increase productivity of carbon steel welding and improve welded properties of heat affected metals, such as low alloy steel and stainless steel.