Double-Electrode Gas Metal Arc Welding

本研究的目的是研究一种创新的电弧机制和由此产生的双电极气体金属弧焊或DE-GMAW的新工艺。该方法是将电弧热的母材部分的生产和控制与电弧热的电极熔化部分的生产和控制分离开来。这种分离的生产和控制机制允许将电弧热的母材部分控制在理想的水平上，以使分离的液滴与母材之间适当地结合，同时可以增加电弧热的电极熔化部分，以最大限度地提高生产率。拟进行的研究包括传热、电弧辐射、流体力学、数值模拟、材料、控制系统/理论、电路设计和计算机硬件/软件开发。本研究的重要性首先在于建立一个知识库，帮助理解和支持有前途的DE-GMAW工艺的运行和优化，帮助美国制造业提高竞争力，特别是与劳动力成本相对较低的国家的竞争力。它还将提供机会，通过具有挑战性的多学科研究和行业合作来培训参与的研究生，并帮助PI开发基于控制的制造的学分和非学分短期课程，这些课程需要培养一流的制造工程师和研究生。此外，PI将为两名优秀的本科生（其中一到两名来自代表性不足的群体）和两名优秀的高中生确定合适的主题，以吸引他们进入研究生院并选择工程职业。

The objective of this research is to study an innovative arcing mechanism and the resulting novel process of double-electrode gas metal arc welding or DE-GMAW. The approach is to separate the production and control of the base metal part of arc heat from the production and control of the electrode melting part of arc heat. This separate production and control mechanism allows the base metal part of arc heat to be controlled at a desirable level for an appropriate bonding between the detached droplet and the base metal while the electrode melting part of arc heat can be increased to maximize the productivity. The proposed studies involve heat transfer, arc radiation, fluid mechanics, numerical modeling, materials, control system/theory, circuits design and computer hardware/software development.The importance of this research first lies in that it will establish a knowledge base which can help understand and support the operation and optimization of the promising DE-GMAW process and help US manufacturing industry improve competitiveness, especially with countries where the labor cost is relatively low. It will also provide opportunities to train participating graduate students through challenging multi-disciplinary research and industry-collaborations and help the PI develop credited and non-credit short courses on control based manufacturing which are needed to educate first-class manufacturing engineers and graduate students. In addition, the PI will identify appropriate topics for two outstanding undergraduate students, with one or two from under-represented groups, and for two exceptional high school students to attract them to graduate school and to choose engineering careers.