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<p>This study investigated the effects of pulsed current under different CO<sub>2</sub> contents in mixture Ar-CO<sub>2</sub> shielding gas on Metal Transfer Frequency (MTF) in Metal-Cored Arc Welding (MCAW) and compared it with Gas Metal Arc Welding (GMAW) using a solid wire. Experiments were conducted for an average current of 250 A with 5–50% CO<sub>2</sub> under DC and DC-pulsed modes. Under DC-pulsed mode, MCAW maintained the MTF of around 190&#xa0;Hz at 5–20% CO<sub>2</sub> (~ 150% of those under DC mode), gradually decreasing to 76&#xa0;Hz at 50%, consistently higher than GMAW, particularly at 25–40% CO<sub>2</sub> (higher by ~ 70&#xa0;Hz). MCAW preserved almost One-Droplet-Per-Pulse (ODPP) up to 35% CO<sub>2</sub>, transitioning to One-Droplet-per-Multi-Pulse (ODMP) beyond this level. The Computational Fluid Dynamics (CFD) simulations at 450 A corresponding to a peak current with Ar <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(+\)</EquationSource> <EquationSource Format="MATHML"><math> <mo>+</mo> </math></EquationSource> </InlineEquation> 20% CO<sub>2</sub> was also carried out to analyze the effect of the relative axial position of the metal-cored tip to the droplet surface (<i>d</i><sub>f</sub>) on arc pressure beneath the droplet in MCAW. The arc pressure in GMAW was 6339&#xa0;Pa. In contrast, that in MCAW decreased from 6119 to 4999&#xa0;Pa with increasing <i>d</i><sub>f</sub> from −&#xa0;0.1 to 0.1&#xa0;mm, facilitating easier droplet detachment compared with GMAW due to decrease in current density under the droplet. Consequently, MCAW allowed a wider CO<sub>2</sub> range (~ 75% higher than GMAW) for the stable ODPP transfer and arc behavior, offering a key advantage for reducing welding costs.</p>

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Elucidation of metal transfer behavior of metal-cored arc welding under the pulsed welding current

  • 期刊论文

  • 发表日期：

    2026年3月19日

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  • Van Hanh Bui,
  • Quang Ngoc Trinh,
  • Shinichi Tashiro,
  • Dang Khoi Le,
  • Kieu Anh Duong Nguyen,
  • Anthony B. Murphy,
  • Kenta Yamanaka,
  • Manabu Tanaka

摘要

This study investigated the effects of pulsed current under different CO2 contents in mixture Ar-CO2 shielding gas on Metal Transfer Frequency (MTF) in Metal-Cored Arc Welding (MCAW) and compared it with Gas Metal Arc Welding (GMAW) using a solid wire. Experiments were conducted for an average current of 250 A with 5–50% CO2 under DC and DC-pulsed modes. Under DC-pulsed mode, MCAW maintained the MTF of around 190 Hz at 5–20% CO2 (~ 150% of those under DC mode), gradually decreasing to 76 Hz at 50%, consistently higher than GMAW, particularly at 25–40% CO2 (higher by ~ 70 Hz). MCAW preserved almost One-Droplet-Per-Pulse (ODPP) up to 35% CO2, transitioning to One-Droplet-per-Multi-Pulse (ODMP) beyond this level. The Computational Fluid Dynamics (CFD) simulations at 450 A corresponding to a peak current with Ar \(+\) + 20% CO2 was also carried out to analyze the effect of the relative axial position of the metal-cored tip to the droplet surface (df) on arc pressure beneath the droplet in MCAW. The arc pressure in GMAW was 6339 Pa. In contrast, that in MCAW decreased from 6119 to 4999 Pa with increasing df from − 0.1 to 0.1 mm, facilitating easier droplet detachment compared with GMAW due to decrease in current density under the droplet. Consequently, MCAW allowed a wider CO2 range (~ 75% higher than GMAW) for the stable ODPP transfer and arc behavior, offering a key advantage for reducing welding costs.