Consumable electrode – additional filler wire arc interaction control under surfacing (DE-GMAW)

Introduction. Arc surfacing through feeding an additional filler wire heated by an additional arc burning between the filler wire and the electrode wire is considered. Under the conditions of such surfacing, the minimization of the input of the remelted substrate metal into the weld metal is studied. The research objectives are to examine the conditions providing self-regulation of this advanced arc surfacing process, and to evaluate control capabilities of the heat impact power on the metal and on the weld metal flow.

Materials and Methods. In solving a wide range of welding and surfacing tasks, it is advisable to use engineering analysis methods based on physicomathematical modeling of processes and phenomena. These include:

• self-regulation of the arc process under joint melting of the electrode and the filler wires;
• assessment of the possibilities to control the heat impact power on the metal and on the weld metal flow during the formation of the weld The features of the arc surfacing of anticorrosive chromium-nickel steels on low-alloy steel are considered in the paper.

Results. New mathematical dependences are proposed that describe physical phenomena under surfacing with an arc interaction between the electrode and filler wire. A physicomathematical model of the joint melting of the electrode and filler wire is developed. It provides determining the values of the control parameters. In addition, you can find out how much heat affects the substrate from:

• heat release in the main arc,
• droplet flows of the weld electrode and filler metal,
• arc plasma

Discussion and Conclusions. It is established how the current and the lengths of the main and additional arcs are affected by the supply voltages. The feed rate of the electrode and filler wire with a diameter of 1.6 mm and 1.2 mm made of Inconel 625 alloy is determined. It is shown what thermal effect the substrate undergoes in this case. It is noted that due to the larger value of the main arc current, the diameter of the electrode wire should be larger than that of the filler wire. The heat flow in the substrate is created mainly by the flow of the weld metal droplets.

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