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<p>Vertical single-side MIG/MAG arc spot welding without pre-punched holes was developed for St3 and 09G2S low-alloy steels with front-sheet thicknesses of 1.5–5.0&#xa0;mm. A staged welding cyclogram with controlled current, voltage, and pulsed wire feeding was used to regulate penetration, filler addition, and thermal history under gravity-affected conditions. Pulsed wire feeding improved arc stabilization after ignition and enabled controlled droplet transfer. Weld geometry depended strongly on pulse frequency and duty-cycle parameter, and a stable operating window was identified at <i>f</i> = 40–60&#xa0;Hz and <i>S</i> = 2, where penetration depth was approximately 1.4–1.6&#xa0;mm and fused area was about 15–19 mm<sup>2</sup>. Tensile-shear testing showed that, for front-sheet thicknesses up to 3.0&#xa0;mm, the hole-free vertical route produced higher mean loads than the pre-punched vertical route and generally comparable or higher mean loads than flat-position welding. Metallographic analysis showed finer weld-metal and HAZ morphology, with less pronounced coarse-grained features under the staged cycle. A dissimilar St3-09G2S joint (2.5/7.0&#xa0;mm) was also produced successfully, with a heat-affected-zone width of about 1.6–1.7&#xa0;mm.</p>

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Vertical single-side MIG/MAG arc spot welding of low-alloy steel sheets without pre-punched holes

  • 期刊论文

  • 发表日期：

    2026年7月7日

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  • Pavlo Goncharov,
  • Mykola Pashchyn,
  • Olha Honcharova,
  • Anatoliy Zavdoveev,
  • Sufian Raja

摘要

Vertical single-side MIG/MAG arc spot welding without pre-punched holes was developed for St3 and 09G2S low-alloy steels with front-sheet thicknesses of 1.5–5.0 mm. A staged welding cyclogram with controlled current, voltage, and pulsed wire feeding was used to regulate penetration, filler addition, and thermal history under gravity-affected conditions. Pulsed wire feeding improved arc stabilization after ignition and enabled controlled droplet transfer. Weld geometry depended strongly on pulse frequency and duty-cycle parameter, and a stable operating window was identified at f = 40–60 Hz and S = 2, where penetration depth was approximately 1.4–1.6 mm and fused area was about 15–19 mm2. Tensile-shear testing showed that, for front-sheet thicknesses up to 3.0 mm, the hole-free vertical route produced higher mean loads than the pre-punched vertical route and generally comparable or higher mean loads than flat-position welding. Metallographic analysis showed finer weld-metal and HAZ morphology, with less pronounced coarse-grained features under the staged cycle. A dissimilar St3-09G2S joint (2.5/7.0 mm) was also produced successfully, with a heat-affected-zone width of about 1.6–1.7 mm.