Analysis of the current wave in the arc phase of metal transfer in the GMAW dynamic feeding process

Originally developed for application in dissimilar joints, the dynamic feeding technology applied to the GMAW process is gaining popularity with applications in wire arc additive manufacturing (WAAM). Given the growing importance of additive manufacturing (AM) in industrial production, it is essential to better understand the main tool of WAAM technology. Acknowledging the limitations imposed on current waveform parameterization in commercial welding sources, this work used a proprietary welding source, named MIG-AD, which allows full control of parameters through dedicated hardware and open-source software. This study focuses on the impact of arc phase parameters on metal transfer, namely arc pulse time, arc pulse current level, and arc base current level. The results show the impact of altering each parameter on droplet formation, wire retraction, detachment frequency, and metal bridge elongation, as well as the stability and quality of the weld bead. This research offers valuable insights for optimizing welding parameters, aiming for greater control and process customization, making it a viable alternative for advanced research in WAAM, cladding, computational simulation, and artificial intelligence applied to welding.