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<p>This study investigates the droplet transfer behavior and weld formation characteristics in single-power double-wire single-arc gas metal arc welding (SDS-GMAW) without spacing under welding currents of 300-600&#xa0;A. High-speed imaging and waveform analysis reveal distinct droplet transfer modes: at 300&#xa0;A, unstable three-pulse-one-drop large-droplet transfer dominates; the range of 350-400&#xa0;A transitions to one-pulse-one-drop transfer with improved stability; 450&#xa0;A introduces a hybrid of large-droplet and spray transfer; currents exceeding 450 A exhibit semi-submerged or submerged arc jet transfer, achieving high-frequency liquid-column transitions. Droplet volume decreases (from approximately 5.4&#xa0;mm<sup>3</sup> at 300&#xa0;A to approximately 2.95&#xa0;mm<sup>3</sup> at 450&#xa0;A) while transfer frequency increases (up to 350&#xa0;Hz at 450&#xa0;A). Weld morphology analysis shows bowl-shaped penetration at 300&#xa0;A, transitioning to finger-shaped penetration above 450&#xa0;A, with penetration increasing linearly with current. Optimal surface smoothness and minimal spatter occur at 500&#xa0;A. The unique co-melting droplet mechanism in SDS-GMAW, driven by electromagnetic contraction and surface tension, eliminates arc interference, enhancing process stability. These findings provide critical insights into optimizing SDS-GMAW parameters for high-efficiency welding applications in constrained spaces.</p>

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Characteristics of Droplet Transfer and Weld Formation in Single-Power Double-Wire Single-Arc Gas Metal Arc Welding

  • 期刊论文

  • 发表日期：

    2026年4月21日

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  • Xiaoli Wang,
  • Yangsen Liu,
  • Qi Zhang,
  • Qingxian Hu

摘要

This study investigates the droplet transfer behavior and weld formation characteristics in single-power double-wire single-arc gas metal arc welding (SDS-GMAW) without spacing under welding currents of 300-600 A. High-speed imaging and waveform analysis reveal distinct droplet transfer modes: at 300 A, unstable three-pulse-one-drop large-droplet transfer dominates; the range of 350-400 A transitions to one-pulse-one-drop transfer with improved stability; 450 A introduces a hybrid of large-droplet and spray transfer; currents exceeding 450 A exhibit semi-submerged or submerged arc jet transfer, achieving high-frequency liquid-column transitions. Droplet volume decreases (from approximately 5.4 mm3 at 300 A to approximately 2.95 mm3 at 450 A) while transfer frequency increases (up to 350 Hz at 450 A). Weld morphology analysis shows bowl-shaped penetration at 300 A, transitioning to finger-shaped penetration above 450 A, with penetration increasing linearly with current. Optimal surface smoothness and minimal spatter occur at 500 A. The unique co-melting droplet mechanism in SDS-GMAW, driven by electromagnetic contraction and surface tension, eliminates arc interference, enhancing process stability. These findings provide critical insights into optimizing SDS-GMAW parameters for high-efficiency welding applications in constrained spaces.