ANALYSIS OF GAS METAL ARC WELDING

USING PULSED CURRENT IN AL5052

GROUP MEMBERS:
1.V.Naveenprakash (713414114072)
2.P.Parthiban (713414114073)
3.T.Santhanakrishnan (713414114093)
4.C.Venkatesh prasanth (713414114116)

GUIDE NAME:Mr.S.Dinesh kumar,M.E.,

Assistant Professor
Department of Mechanical Engineering
 ABSTRACT
In this experimental work, aluminium alloy (5052) weldments were made
using Gas Metal Arc Welding (GMAW)with pulsed current and non- pulsed
current at different frequencies 2Hz, 4Hz, 6Hz. Non-destructive tests like
radiography, liquid penetrate test were conducted, evaluated and compared
with pulsed and non-pulsed current welding at different frequencies of
thickness materials (2mm of 5052 aluminium alloy). The aim of this
experimental work is to see the effect of pulsed current on the quality of
weldments. The experimental results pertaining to different welding
parameters for the above material using pulsed and non-pulsed current
GMAW are discussed and compared.
 COMPONENTS

1. MIG welding equipment

2. Alumiminium(5052) alloy plates

3. Demon-E4043 electrode

4. Penetrants
 INTRODUCTION
 Gas metal arc welding (GMAW) is a welding process that has been
commercially available for around 60 years. The basic operation of
the GMAW process occurs when an electrical arc is established and
maintained between a base material and a continuously feed wire
electrode.

 The molten weld pool is shielding from the atmospheric conditions

by an envelope of shielding gas that is flowed continuously around
both the wire filler metal feeding in the weld pool and the weld pool
itself.
The heat of the electrical arc serves to locally melt the base metal as well
as melt the wire filler metal that is being fed into the weld. There are two
entities at play in the GMAW process:

1. Burn Rate: This refers to the rate, inches/minute (in/min) or

meters/minute (m/min), at which the wire filler metal is melted or
consumed by the thermal energy of the welding arc.

The primary variables that control the thermal energy of the arc are the
welding current, welding voltage, and shielding gas composition.
2. Feed Rate: This simply refers to the rate, again in in/min or m/min, that
the wire filler metal is feed into the weld.
GAS METAL ARC WELDING
There are two main variables of the GMAW process that affect both the
penetration profile into the base material and weld bead profile above the
base material for a given weld:

1. Welding Current.

2. Welding Voltage.

The information below observes the very basic effects that the welding
current and welding voltage variables have on the weld penetration profile
in the base material and the weld bead profile that lies above the base
material. The base material used in for the following welds is cold rolled
1.018 bar stock and the shielding gas is 90% Argon – 10% CO2.
 LITERATURE REVIEW
 A.Raveendra, Dr.B.V.R.Ravi kumar., “Effect of pulsed current on
welding characteristics of EN 19 alloy steel using gas tungsten arc
welding (2013)’’ in the alloy steel EN19 more porous found in
higher thickness weldments with pulsed welding that the non-pulsed
current weldments, because the molten metal remain in
solidification phase for longer duration in non-pulsed then the gas
are escaped and minimized the porous in weldments.
 D. W. Becker and C. M. Adams, jr et al., “The role of pulsed GTA welding
variables in solidification and grain refinement’’. Then reduction of grain
size in mild steel was shown to be possible by proper selection of pulsed-
current welding parameters
BLOCK DIAGRAM
PROBLEM IDENTIFICATION
 From these test the paper says that porosity were increased with increase in

thickness, these defect may affect the entire strength of the metal.

 Here a new approach of technique Gas Metal Arc Welding (GMAW) and

same test were done to these materials at variable in thickness 2mm by

varying the frequency in 2Hz, 4Hz and6Hz. From these experiments we are

going to show that aluminium is a good suited metal for replacing the Gas

Metal Arc Welding (GMAW).

 METHODOLOGY

 The work pieces were made of 5052 aluminium alloy of various

thicknesses 2mm. The test specimens were machined to the required size
and welded with pulsed and non-pulsed current GMAW process. Filler wire
material of ER4043 was used during the welding, which reduced the weld
cracks and produced the good strength and ductility than other filler metals

 These filler metals melt at a temperature lower than that of the base metal,
for this reason it yields during cooling, since it remains more plastic than
the base metal and relieves the contraction stresses.
 In general, RT is method of inspecting materials for hidden flaws by using
the ability of short wavelength electromagnetic radiation (High energy
photons) to penetrate various materials the intensity of the radiation that
penetrates and passes through the materials is the either captured by a
radiation sensitive films (Film radiography) or by a planner array of
radiation sensitive sensor (Real time radiography) Film radiography is the
oldest approach, it still the most widely used in NDT.

 In liquid penetrate test having various stages are:pre cleaning, application

of penetrant,excess penetrant removal,inspection,post cleaning.
 ADVANTAGES
 Leads to produce less porosity in welding

 Melting point is low compare to EN19

 High welding is obtained.

 Less material used is leads to increase in economy

 5000 series Aluminium alloy best for welding and produce the best result

 Aluminium and its alloy is widely used one in major fields

 It provides greater efficiency.

 Welding productivity is double as compared to shielded metal arc welding.

 APPLICATIONS

 It is used in primary for structural application in sheet metals ex. Motorcar

manufacture, ship building, aircraft engineering, pressure vessels, pipes.

 It is used in primary for structural application in plate metals