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<p>To address the severe arc interference between the two arcs in double-wire gas metal arc welding (GMAW), a double-wire variable-polarity double-pulsed GMAW (VPDP-GMAW) system specifically designed for aluminum (Al) alloy welding was developed. By employing a digital oscilloscope and a high-speed camera, the voltage and current waveforms, as well as arc profiles, were synchronously captured under different direct current electrode negative (DCEN) ratios of the pulse cycle. The stability and dynamic behavior of the double arcs were systematically evaluated using approximate entropy (ApEn), sample entropy (SampEn), and voltage-current (<i>U‑I</i>) curves. The results demonstrated that the electrode negative (EN) ratio had a pronounced influence on arc shape and stability. Within the range of 0 to 40%, arc stability improved with increasing EN ratio. However, when the EN ratio approached 50%, arc stability decreased, and arc interruption phenomena became more frequent. These interruptions mainly occurred during the switching from the electrode positive (EP) base to the EN current stage, especially in the weak pulse phase of the double-pulse cycle. The <i>U-I</i> curves showed that the arc exhibited an inductive characteristic, thereby enhancing the re-ignition capability during polarity switching. The arc was most stable in the EN current stage, whereas its stability was lowest in the EP base current stage. During the process of polarity switching, the switching from the EN to the EP peak current stage exhibited strong continuity, whereas the switching from the EP base to EN current stage exhibited stagnation.</p>

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Arc characteristics in double-wire variable-polarity double-pulsed GMAW of aluminum alloy

  • 期刊论文

  • 发表日期：

    2026年7月16日

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  • Kaiyuan Wu,
  • Yihui Zhao,
  • Zhenhao Li,
  • Yutao Chen,
  • Haoran Yang,
  • Xiaobin Hong

摘要

To address the severe arc interference between the two arcs in double-wire gas metal arc welding (GMAW), a double-wire variable-polarity double-pulsed GMAW (VPDP-GMAW) system specifically designed for aluminum (Al) alloy welding was developed. By employing a digital oscilloscope and a high-speed camera, the voltage and current waveforms, as well as arc profiles, were synchronously captured under different direct current electrode negative (DCEN) ratios of the pulse cycle. The stability and dynamic behavior of the double arcs were systematically evaluated using approximate entropy (ApEn), sample entropy (SampEn), and voltage-current (U‑I) curves. The results demonstrated that the electrode negative (EN) ratio had a pronounced influence on arc shape and stability. Within the range of 0 to 40%, arc stability improved with increasing EN ratio. However, when the EN ratio approached 50%, arc stability decreased, and arc interruption phenomena became more frequent. These interruptions mainly occurred during the switching from the electrode positive (EP) base to the EN current stage, especially in the weak pulse phase of the double-pulse cycle. The U-I curves showed that the arc exhibited an inductive characteristic, thereby enhancing the re-ignition capability during polarity switching. The arc was most stable in the EN current stage, whereas its stability was lowest in the EP base current stage. During the process of polarity switching, the switching from the EN to the EP peak current stage exhibited strong continuity, whereas the switching from the EP base to EN current stage exhibited stagnation.