Session 10: Joining Processes and Parameters Control - II

D. Modified GMAW for Spray Transfer with Pure CO2 Shielding Gas
by Erik Soderstrom, Dr. Patricio Mendez, Colorado School of Mines

Spray transfer is a very desirable mode of metal transfer in GMAW due to the
high deposition rates and weld quality. However, this mode is achieved only with high
concentrations of argon shielding gas. Carbon dioxide is the main alternative to argon,
but spray transfer has not been achieved using this gas. The reasons are not
completely understood and are the focus of this research project. The goal is to
achieve spray transfer in GMAW while using pure CO2 shielding gas.
Previous analysis of GMAW using mixtures of Ar-CO2 suggests the globular to
spray transition current increases with the amount of CO2 and decreases with smaller
electrode diameters. This implies that high current densities might be the key to
achieve spray transfer. Both experimental and theoretical analysis indicate that such
high current density can lead to impractically high welding currents, contact tip damage
(burn back), and the possibility of an unstable arc (repelled transfer, rotational transfer).
This research is currently a work in progress that takes a radically new
approach that is based on previous work, but utilizes ideas that have not been explored:
use normal welding currents (e.g. 250 A) with very thin wires (0.023” or less) at very
high wire feed speeds (on the order of 1500 in/min). It is expected that the electrode
extension will be fairly short with these parameters (0.25” or less). With these
conditions, it is expected that the arc will completely envelop the droplet, which is one of
the conditions of spray transfer agreed upon by many researchers.
To achieve these conditions, a new contact tip is being designed and built that
can handle thin wire at high speeds, prevent burn back, and withstand the high
temperatures of the arc with a short electrode extension. Also, a new wire feeding
mechanism is being designed that can handle the small wires and high feed rates. An
industrial constant voltage welding power source is used. The results of this research
should immediately be applicable to commercial welding machines, with the only
changes being made to the contact tip and wire feeding mechanism.
Results of this work will also be useful to other welding related fields, such as
fume generation (a product of thermal balance in the electrode) and other shielding
gases such as helium. New useful transfer modes might be discovered, and even if
true spray transfer is not achieved, the droplet rate expected from the modified process
would be as high or higher than in spray transfer in Argon, potentially bringing the same
benefits.