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<p>A novel welding process that combines variable polarity pulsed gas metal arc welding (VP-GMAW) and high-frequency pulsed (HFP) welding is proposed to improve the weld quality of aluminum (Al) alloy. The effect of HFP frequency on the arc shape, stability, and weld formation of Al alloy in VP-GMAW is investigated. The arc shape at different HFP frequencies is analyzed using high-speed photography, and the arc profile is extracted by gray processing. It is found that the arc-projected diameter decreases gradually with increasing HFP frequency. The <i>U</i>-<i>I</i> characteristic curve is used to analyze the stability of the arc load. The curve before and after polarity switching is more compact after superimposing HFP, indicating that the superimposing HFP improves the stability of variable polarity arc. As the HFP frequency increases, weld penetration deepens, weld width narrows, and the penetration-to-width ratio (<i>PW</i>) increases. When 30&#xa0;kHz HFP is superimposed, the <i>PW</i> reaches its maximum of 18.3%. When combined with the double circulation model of the weld pool, the HFP can improve the convergence circulation and penetration depth. The divergence circulation is weakened, and the width is reduced. In addition, high-frequency vibration can accelerate the flow of molten metal in the weld pool and help to deepen penetration.</p>

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Effect of high-frequency pulse frequency on arc characteristics and weld formation of aluminum alloy in variable polarity high-frequency pulse GMAW

  • 期刊论文

  • 发表日期：

    2025年3月19日

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  • Kaiyuan Wu,
  • Zitao Liu,
  • Qianrun Chen,
  • Yongming Wu,
  • Ziwei Chen,
  • Xiaobin Hong

摘要

A novel welding process that combines variable polarity pulsed gas metal arc welding (VP-GMAW) and high-frequency pulsed (HFP) welding is proposed to improve the weld quality of aluminum (Al) alloy. The effect of HFP frequency on the arc shape, stability, and weld formation of Al alloy in VP-GMAW is investigated. The arc shape at different HFP frequencies is analyzed using high-speed photography, and the arc profile is extracted by gray processing. It is found that the arc-projected diameter decreases gradually with increasing HFP frequency. The U-I characteristic curve is used to analyze the stability of the arc load. The curve before and after polarity switching is more compact after superimposing HFP, indicating that the superimposing HFP improves the stability of variable polarity arc. As the HFP frequency increases, weld penetration deepens, weld width narrows, and the penetration-to-width ratio (PW) increases. When 30 kHz HFP is superimposed, the PW reaches its maximum of 18.3%. When combined with the double circulation model of the weld pool, the HFP can improve the convergence circulation and penetration depth. The divergence circulation is weakened, and the width is reduced. In addition, high-frequency vibration can accelerate the flow of molten metal in the weld pool and help to deepen penetration.