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Advanced gas metal arc welding processes

Article in The International Journal of Advanced Manufacturing Technology · July 2013

DOI: 10.1007/s00170-012-4513-5

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Int J Adv Manuf Technol (2013) 67:655–674
DOI 10.1007/s00170-012-4513-5

ORIGINAL ARTICLE

Advanced gas metal arc welding processes

P. Kah & R. Suoranta & J. Martikainen

Received: 2 May 2012 / Accepted: 11 September 2012 / Published online: 30 September 2012
# Springer-Verlag London Limited 2012

Abstract There is an increased requirement in the automo- process can face difficulties in welding some materials.
tive, food and medical equipment industries to weld heat- The need to widen the range of weldable materials and to
sensitive materials, such as thin sheets, coated thin plates, increase productivity has contributed to new arc welding
stainless steel, aluminium and mixed joints. Nevertheless, processes modifications. Although the modifications techni-
relevant innovations in arc welding are not widely known ques were introduced at the end of the nineteenth century,
and seldom used to their maximum potential. In the area of widespread implementation of the arc welding process was
gas metal arc welding welding processes, digitalisation has not possible because of the poor capability of power sources
allowed integration of software into the power source, wire to control and provide the required dynamic and static
feeder and gas regulation. This paper reviews developments characteristics. The need to develop the gas metal arc weld-
in the arc welding process, particularly the effect of the set- ing (GMAW) process became associated with technological
up of the welding process parameters on waveform deposi- development of the power source.
tion. It is found that good weldability, good mechanical joint In vehicle construction work, joints between steel and
properties and acceptable process efficiency can be obtained aluminium are also increasingly being used. In the iron/
for thin sheets through advanced power source regulation, aluminium phase diagram, iron or steel and aluminium offer
especially over short circuiting, controlled polarity and elec- virtually no solubility with one another. In each mixed ratio,
trode wire motion. The findings presented in this paper are Fe/Al phases occur with brittle characteristics. Experience
valuable for waveform and deposition prediction. The need therefore shows that a proportion of Al/Fe phases in the
is furthermore noted for an algorithm that integrates gas molten material of over 10 % must be avoided in all cases.
flow parameters and wire motion control, as well as a When using zinc as the filler material, a joint can be created
variable sensor on the tip of the electrode, permitting flex- between these two materials, where the aluminium is par-
ibility of control of the current and the voltage waveform. tially melted, whereas the steel, to avoid brittleness in the
molten material, may only be moistened. This means that a
Keywords Arc welding processes . GMAW . Low heat welded joint is created on one side and a brazed joint on the
input . Productivity . Transfer mode . Waveform . Current . other [1].
Voltage The pulse gas metal arc welding (GMAW-P) method can
be used for any type of ferrous as well as non-ferrous
material, even for sheet metal welding and positional weld-
1 Introduction ing, which is very much challenging with other welding
processes. It can reduce corrosive tendency, hot cracking,
Arc welding is a group of welding processes in which the spattering and distortion due to the pulsed nature of current.
arc generated by electric power is used to melt the wire and However, this process depends greatly on the right selection
weld pool to allow the joining of parts. However, the of pulse parameters, as the latter affect the weld microstruc-
ture and porosity content of the weld due to their influence
on weld thermal cycle and arc characteristics [2].
P. Kah (*) : R. Suoranta : J. Martikainen
Modern welding power sources have benefited from
Lappeenranta University of Technology,
P. O. Box 20, 53851 Lappeenranta, Finland developments in electronics and the introduction of thyris-
e-mail: [email protected] tors, transistors and other components. The transistor, for
656 Int J Adv Manuf Technol (2013) 67:655–674

the type of the arc process because their values directly influ-
ence the droplet transfer mode and the stability of the process.
The main difficulty with conventional power sources was
control of these variables during the process. Electronic and
digital controls enhance the accuracy of the arc. In the 1990s,
developments in computer technology made possible the
design unlimited amount of waveforms aimed to improve
the timing of arcing and metal deposition [3, 4].
The metal transfer mode is controlled by power output
regulation. The International Institute of Welding proposed
in 1976 a classification of droplet transfer and welding pro-
cesses (Table 1) published later by [5, 6]. Technological
innovation brought variation to the welding process and [7]
proposed a reassessment of welding with three main catego-
ries: natural metal transfer, controlled transfer and extended
operating techniques (Tables 2 and 3) [8].
In earlier wire feeds, the motion was constant and the
Fig. 1 Arc types and their working ranges, solid wire (d01.2 mm)
shielding gas: argon-rich mixtures [5]
wire speed was adjusted to the process. New developments
have synchronised both the power source and the wire
feeder to reach an optimised molten material transfer mode.
example, can be used as a variable resistor or as an elec- The process is called, “mechanically assisted droplet depo-
tronic switch and modern power sources can include an sition,” which is applied in controlled short circuit by
electronically analogue controlled chopper or an inverter. retracting the wire from the short circuiting [9, 10]. In
This technology has widened the range of adjustments in the addition, the contact tip-to-work distance (CTWD) is inte-
power source, made welding suitable for robot applications, grated into the control of the arc welding process so that the
and enabled the digitalisation of feedback from millisecond arc length is not disturbed by the irregularity of the surface
to nanosecond and intelligent control of the welding pro- welded and handling monitoring during the manual process
cess. The inverter is a key improvement in the modern power [11]. Another important factor in the welding process is
source because it quickly responds to digital feedback control control of the shielding gas. Regulation of the flow has
and it has dramatically changed the features of arc control [3, become part of the algorithm to optimise the flux according
4]. This study focuses on the principles behind the new to requirements sensed on the tip and weld pool [12].
processes, highlighting the key improvement in terms of The aforementioned innovations have given more options
droplet transfer mode control, current and voltage control, to the welder; rather than following pre-set welding parame-
wire feeder control and gas shielding control. A comparison ters established during design of the power sources, determi-
of each process is made with the traditional GMAW process nation of the welding parameters now depends on the
and between the different approaches. electronic control or the computer. This improvement has
Figure 1 shows the metal transfer mode function of the given rise to new opportunities in welding heat-sensitive
welding voltage (V) and current (A) outputs, which determine materials, such as aluminium and stainless steel, and enabled

Table 1 IIW classification of

metal transfer [6] Transfer modes Welding process

Free flight transfer Globular Drop Low current GMA

Repelled CO2 shielded GMA
Spray Projected Intermediate current GMA
Stream Medium current GMA
Rotating High current GMA
Explosive SMA (coated electrode)
Bridging transfer Short-circuiting Short arc GMA
Bridging without interruption Welding with filler wire addition
Slag protected transfer Flux wall guided SAW
Other modes SMA, cored wire, electroslag
Int J Adv Manuf Technol (2013) 67:655–674 657

Table 2 Classification of controlled transfer mode [8]

Metal transfer modes Welding process

Controlled spray Pulsed transfer GMAW using variable frequency pulse and drop spray transfer
Controlled short circuiting Current controlled dip transfer GMAW using current controlled power source
Controlled wire feed short circuit mode GMAW with wire feed oscillation

joining of dissimilar materials and thin sheets or plate materi- developed by KEMPPI Company and is based on control of
al. The precision and flexibility of machine control has made it the power source. An initial version of the process was first
possible to apply a variety of methods and has also permitted introduced in 2005 and was called FASTRoot. Recently, the
optimisation of the choice of electrode diameters, shielding welding devices and software were coupled and the process
gas and material quality, with a significant impact on both the renamed WiseRoot. The power source control enables reg-
economics of welding and service reliability [8]. ulation of the short circuit and allows accurate timing of the
The need to increase productivity has resulted in the transmission of the filler drop from the filler into the weld
development of high-power range transfer modes. One pool. The prefix wise indicates a new approach which
example of such a transfer mode is the rotating arc, which integrates improvement in efficiencies and a brand new
is mainly performed in the T.I.M.E or RapidMelt [13, 14] welding process supported by software. The concept com-
process. Distortion, a consequence of the high energy load, prises the elements WiseRoot, WiseThin, WisePenetration
is, however, one of the limits of the process. and WiseFusion. In this paper, attention is, however, given
primarily to the two first concepts which make up the new
short arc mode [15–17].
2 Advanced power source regulation In the WiseRoot process, the power source is monitored
by the wave of the current, which can be analysed in two
This section identifies the main advances that have occurred main parts; the short circuit and the arc period (see Fig. 2).
in power source regulation of the short circuiting process. In the short circuit period, the filler wire is transmitted to the
The designs of new arc welding processes aim to overcome weld pool that materialises on the current curve by a short
the limitations of traditional short arc waveform by enabling peak at the time when it contacts the weld pool. The current
new shapes of the arc curve. The power sources benefit from is maintained at this required level to permit the step to be
enhancement in digital control and upgraded software, completed. The current then increases suddenly, to make
which enables monitoring of every aspect of the arc. The drop detachment possible from the filler material. The drop-
short circuiting is predictable and can be set at a specific let is formed by maintenance of the current at that level
time. Moreover, the molten material transfer can be handled during a certain period of time, followed by a moderated
so that spatter is minimised. decrease of the current till the detachment occurs. As soon
as the transmission to the weld pool has occurred, a second
2.1 WiseRoot™ process phase of the current increase begins and initiates the arc
period [15, 16].
The WiseRoot process is a metal inert gas (MIG)/metal The arc period is initiated by an increase of the current to
active gas (MAG) modified short arc circuit welding process the desired level, forming the weld pool and guaranteeing

Table 3 Classification for

extended operating modes Metal transfer modes Application
techniques [8]
Short circuiting GMAW Extended stick out GMAW High deposition short circuit transfer GMAW
Low frequency pulsed Pulsed mean current for gap filling
Pulsed transfer GMAW Multi-wire Multi-wire GMAW
Low frequency pulsed Modulated pulsed transfer welding of aluminium
Variable polarity Welding of thin sections and single sided root runs
Spray transfer GMAW Rotating spray High current extended stick out
Electrode negative Flux cored wire or special gas mixture
Spray transfer SAW Electrode negative
Extended stick out
AC/variable polarity
658 Int J Adv Manuf Technol (2013) 67:655–674

Fig. 2 Current waveform of

WiseRoot™—conventional
short arc and sequence of
the arc [15]

the penetration of the weld root. The current is then reduced to the five states of the droplet and the arc. Figure 3 shows
to an appropriate level to ensure timely formation of the the waveform and images from a high-speed camera of the
droplet during the next short arc [15, 16]. Table 4 presents tip of the drop detachment from the filler wire to the weld
an example of a root pass when welding an X65 pipe. The pool and the re-ignition of the arc. The process can be
process allows satisfactory joints to be achieved with reduced detailed as follows [20]:
heat input [18].
& Background current: The background current is in a
WiseThin is a MIG/MAG welding process which can be
range from 50 to 100 amps to keep the arc, as shown
considered as an extension of WiseRoot™. The principle is
in A, in an arc burning period and to heat the base metal.
the same, i.e. usage of a modified short arc. However,
When the filler wire is in contact with the weld pool in
WiseThin differs from WiseRoot in that it is optimised for
B, the current is suddenly decreased to form the droplet.
welding of sheet metal [16]. The process is capable of
& Pinch current: The pinch current is applied to permit the
achieving similar welds with 5–25 % less heat input than a
detachment of the molten filler while monitoring the
conventional short arc and maintains the same heat input as
shrinking section in C. In D, when the detachment is
a laser welding process [16].
likely to occur, the power source control reacts by
reducing the current to about 45–50 A to allow a smooth
2.2 Surface tension transfer™ process
break of molten metal from the tip of the electrode.
& Peak current: The peak current is applied, in E, just after
Surface Tension Transfer (STT™) [19], invented by Lincoln
the drop has separated, to allow generation of the plasma
Electric, is a GMAW process based on control of the short
that pushes the weld pool down, to avoid unexpected
circuit transfer process. The process performs without
shorting, and to heat the puddle and the joint.
changes to the voltage settings. Instead, the heat is adjusted
& Tail-out: The tail-out following E is an exponential
by current control independent of the wire feed speed.
decrease by the current control to regulate and initiate
Therefore, the change in electrode length has no consequen-
the next detachment and re-ignition from the “back-
ces on the heat value [20]. STT devices are equipped with
ground current”.
electronic technology which enables optimisation of the
waveform and arc characteristics for a specific application. Table 5 shows examples of results from experiments
In addition, the setting programme integrates relevant factor, performed on high-strength low-alloy SA 516 of 5 mm
such as the joint type, material and thickness, rate of travel, thickness and on a 15Mo3 steam boiler component. The
electrode size and type, as well as the specific arc shielding studies [20, 21] showed the usability of STT on sensitive
gas. The process is claimed to combine the best aspects of heat material with CO2 as shielding gas, in the first case, but
the short arc and TIG processes in a single process [21]. also with an argon and CO2 mixture. In addition, the results
The current control follows a particular waveform, the showed directly proportional changes in the fume emission
curve can be considered in four main stages that correspond of STT with wire feed speed. Analyses of the weld bead

Table 4 Example welding parameters with the WiseRoot process

References Material Groove Wire Shielding gas Wire speed Welding speed Position
(m/min) (m/min)

[18] X65 V 50° 1.0 LMN Ni1 Ar+18 % CO2 3.5–3.9 75–130 –
D0780 mm Width (4.5 mm) and
t045.5 mm height (0.5 mm)
(Pipe)
Structural steel tube I gap 4 mm 1.0 mm G3Si1 – 3.0 or 2.8 – Vertical position
D0110 mm up to down
t04 mm
Int J Adv Manuf Technol (2013) 67:655–674 659

Fig. 3 Current waveform

control of STT and
corresponding drop and short
arc images [22]

revealed better penetration and superior microhardness. & Blink: Upon pinch detection, rapidly decrease the cur-
STT showed the lowest fume formation rate and excellent rent. Pinch detection occurs before the short clears. The
weld bed geometry at higher wire feed speeds [22]. The inverter “shuts off” and current decays to a low level
process was successfully applied in steam boiler produc- before the short circuit breaks.
tion, with acceptable joint output quality and higher effi- & Ball: Increase current to form a ball for the next short
ciency in the root pass compared to a conventional GMAW circuit.
process [23]. & Background: Drop the current to a low enough level to
allow a short circuit to occur.
2.3 Regulated metal deposition (RMD™) process & Pre-short: If the background current exists for a rela-
tively long time, the pre-short period drops current to an
Miller Electric Mfg. Co introduced, in 2004, a new welding even lower level to make sure arc force does not push
technology process called RMD or regulated metal deposi- the puddle back (e.g. prevents excess agitation).
tion. The technology is based on an advanced software
According to the manufacturer, the RMD software
application for modified short circuit transfer GMAW
programme, working with an inverter-based welding system
(MIG welding) that monitors the electrode current in each
and closed-loop feedback, closely monitors and controls the
step of the short circuiting. The wave profile depends on the
electrode current at speeds up to 50 μs (50 millionths of a
material being welded, although the typical waveform shape
second). Moreover, the software accurately adjusts the re-
remains, as shown in Fig. 4. The RMD approach is illus-
quired speed and gas combination for a specific wire diam-
trated in different steps as follows [24]:
eter. Thus, based on the heat history of the tips, it predicts
& Wet: Let the ball on the end of the wire wet-out to the future arc conditions and controls the droplet transfer ac-
puddle. cordingly [24, 25]. Table 6 presents an example of RMD
& Pinch: Increase the current to a level high enough to use, showing the ability to weld line pipe alloy steel P5B
initiate a pinch effect. and P91 grade with a significant drop in heat input. The
& Clear: Maintain and slightly increase the pinch current to decrease in heat input also benefits line pipe carbon steel
clear the short circuit while simultaneously watching for X52 grade [26]. Experiments with the process on a nickel
pinch detection. alloy have also resulted in a successful root pass [27].
660 Int J Adv Manuf Technol (2013) 67:655–674

Wire speed Welding speed Peak current Background Volt Gas flow rate

10

15
(L/min)

17
20
23
26
29
current (%)

100 (40)
125 (50)
150 (60)
175 (70)
200 (80)
65
250

265

Fig. 4 a RMD current waveform and b current wave Form [24]

2.4 Cold Arc™ process

150
–

The Cold Arc concept is a controlled short circuiting metal

(m/min)

transfer mode patented by EWM Hightec Welding GmbH and

presented in 2004. The new MIG/MAG welding process takes
advantage of a new type of highly dynamic inverter switching,
5.00
6.24
7.51
8.76
10.00
(m/min)

combined with very fast digital current control. The digital

3

signal processor is used to control the instantaneous extraction

of the power just before re-ignition in a period of less than 1 μs;
Ar+18 % CO2
Shielding gas

the peak power in the arc is dramatically reduced when the

short arc is re-ignited [28]. Figure 5 compares the waveform of
the conventional and the Cold Arc process. The first two steps
CO2

are similar to conventional short circuiting; during the arc

AWS A5.29, Class E 110 T5-K4

burning phase, the electrode approaches the work piece with

the current and voltage maintained at the required steady level.
The arc phase stops when the electrode touches the work piece.
Then the voltage drops suddenly to almost zero, while the
current increases sharply to allow the pinch effect. The current
is decreased dramatically to permit a smooth break of the bridge
Wire (mm)

1.2

of the molten metal, preventing spatter. Immediately after the

arc ignites, the outputs is reduced (Fig. 5a) in a dynamic and
controlled way. After the arc has been stabilised, the current is
raised slightly for a defined short period of time, known as melt
Bead on plate

pulse, to create a regular separation. In addition, the melt pulse

Table 5 Example welding parameters with the STT process

15Mo3 (steam boiler) Butt joint

creates a melting cone on the edge of the electrode, therefore

Groove

guaranteeing smooth continuity of the process [28].

The Cold Arc process has been applied in butt jointing of
thin sheet plate aluminium grades such as 6XXX, 2XXX
and 5XXX, presented in Table 7. Although the manufacturer
HSLAA SA516

claims other material grade, the experiment on aluminium

showed improvement within standard range concerning
Material

FCAW with STT mode 5 mm

mechanical and micro-structure of the joint. Cold Arc, in

limited condition of iron/aluminium diagram phase exhibits
ability of mixed joint [29].

2.5 ColdMIG™ process

References

The ColdMIG process is patented by MERKLE. The process is

a modified short arc process enabled by the use of software to
[22]

[23]

monitor the waveform. The application is one of the options in

Int J Adv Manuf Technol (2013) 67:655–674 661

Table 6 Example welding parameters with the RMD process

References Material Groove Wire Shielding gas

[77] P5B grade of P91 Bead on plate ER90S-B9 Ar 90 %+10 % CO2

[27] C-2000 thickness 6.35 mm Root pass Diameter 1.14 mm 10 % helium–0.4 %
flat position AWS G 1 CO2 –balance argon
Gap:1.27–1.5 mm Single V groove, 70° Travel speed: 0.5 m/min
included angle
Root land:5.08 mm 15.4 V WFS: 5.7 m/min
135 A

a multi-process power source. The process is characterised by resulting in a highly stable and focused short arc, colder weld-
optimization of the voltage and current waveform. Figure 6 ing, lower heat input, less distortion and lower power consump-
shows, in the same frame, a conventional short circuit and the tion. In addition, the process includes intelligent control of the
ColdMIG curve. During the short circuit cycle, considerable flow shielding gas rate [32, 33].
increase in the current reduces the voltage to about zero to allow The typical current and voltage waveforms of IAC, shown
the droplet detachment. The short circuit period is dramatically in Fig. 7, are significantly different from those of a conven-
reduced compared to a conventional short arc, which gives a tional short circuit. During the arcing cycle, the voltage is
new shape to the waveform in this section, for voltage as well as maintained at a considerable level while the current is sharply
current waveform. The time of the current in this period is decreased and after the re-ignition steadily reduced to a low
reduced and occurs faster. The consequence is that the short level. In this stage, in a conventional short circuit, both the
circuiting cycle is considerably reduced, which leads to a drop current and voltage are maintained at a right level. During the
in heat input generated by the short arc [30, 31]. Furthermore, to short circuiting cycle, the voltage is dramatically reduced and
permit a smooth break of the molten bridge and a stable start of the current is increased to allow the pinch effect. After reach-
the arc, the current is dramatically decreased during the transi- ing the peak, the current and voltage are suddenly reduced for
tion between the molten metal detachment and the re-ignition a cold transfer of the molten metal and stable transition for the
of the arc [31]. re-ignition of the arc. Table 8 presents an example of setting of
mild steel suggested by the manufacturer. The manufacturer
2.6 Intelligent Arc control™ process claims the arc control for mild steel, stainless steel and other
grades in the software package [32, 33].
Intelligent Arc Control (IAC™) is a modified short arc process;
the result of 3 years research by Migatronic and released in 2.7 Super-imposition™ process
2010. The process benefits from the latest improvements in
inverters and digital control. IAC registers every welding cycle The Super-imposition (SP-MAG) process is a modified
and adjusts the arc 50,000 times per second. The software short arc circuit patented by Panasonic. SP-MAG aims to
models and optimises dynamical parameters of the short arc, overcome some of the limitations of conventional short

Fig. 5 Principle of a Cold Arc

voltage and current waveforms
and b Cold Arc power at
re-ignition [30]
662 Int J Adv Manuf Technol (2013) 67:655–674

Table 7 Example welding

parameters with the Cold Arc References Material Groove Wire (mm) Welding speed Current Volt
process
[29] 6XXX Butt joint 0.52-mm AlSi5 40–80c m/min 68 A 11.6 V
2XXX 1.2 mm
5XXX AlMg4.5MnZr
AlMg5
1.2 mm

circuiting and constant voltage (CV) processes, such as 2.8 Controlled bridge transfer™ process
spatter, low speed and low heat input. The TAWERS robot
series claims to successfully gather in one process the bene- The controlled bridge transfer process (CBT) is a modi-
fits from pulse and CV approaches [34–36]. Figure 8a and b, fied short circuiting process which aims to reduce the heat
presenting the waveform of the current and voltage, show input and spatter when the molten metal touches the
improvements in control of the short arcing. During the puddle and when the droplet separates from the electrode.
short arc cycle, the shape of the current and voltage are Figure 9 shows the current waveform of the process. The
similar to conventional processes. There are two main dif- process senses the contact of the electrode with the melt-
ferences in the arc burning. Firstly, so-called super- ing pool and reduces the current dramatically to avoid
imposition (SP) which time is shortened. The SP control spatter. The second switching occurs at the necking
prevents the short arc after re-ignition; the tip is made round period; the process senses the decrease of the cross-
to allow a smooth start of the arc. Secondly, so-called hyper- section by the pinch effect and drops the current rapidly
stabilisation (HS), which is characterised after the pea, by a to allow only the surface tension to perform the molten
dramatic reduction of the current wave curve and a sudden transfer in the puddle. The method overcomes disturban-
increase, then followed by a steady drop along the arcing ces as arising from wire extension, welding speed, weld-
period. In addition, the HS control suppresses the vibration ing position, and the size, shape and viscosity of the
of the molten pool, shortly after re-ignition, to prevent short- molten droplet, which occur in timed squeezing of the
arc. Again, this period is shorter than in a conventional short drop. The process has been proved to be able to weld
circuit [34–36]. stainless steel with a stable arc in an argon-rich environ-
An experiment was carried out in the automobile industry ment [38]. In addition, electro-negativity (EN)-CBT has
[37] to investigate robotic MAG process welding parameters been applied successfully and allows low heat input weld-
(Table 9). The aim was to optimise the process parameters in ing. CBT was suggested by a group of researchers [38]
similar welding of steel and dissimilar welding with high and is now implemented under the name metal transfer
strength and dual phase steels. The thickness of the work- stabilisation by Panasonic Corporation, with the aim of
pieces differed from 1.2 to 3.0 mm. In addition, different improving the CO2 welding process in MAG [38].
combinations with various thicknesses were welded. The Table 10 presents details of experiments performed with
conventional short arc current waveform was used for com- AISI304L on a lap joint, the section of which varied from
parison with the SP-MAG waveform. The result showed 0.6 to 2.0 mm. The results showed low distortion and signi-
that robotic MAG welding of similar and dissimilar material ficant improvement in mechanical properties and micro-
joints can give welds with satisfactory mechanical and structure. In addition, low-spatter and low-fume emission
structural properties, even with variable gap (0–2 mm). were noted compared to the conventional process [39].

Current

Voltage

Fig. 6 Comparison of conventional short arc and ColdMIG current Fig. 7 Voltage and current waveform of the droplet transfer sequence
and voltage waveform [31] of Intelligent Arc Control—Sigma Galaxy [32]
Int J Adv Manuf Technol (2013) 67:655–674 663

Table 8 Example welding parameters with the Intelligent Arc Control process

References Material Groove Wire Shielding gas Welding speed Current Volt

[33] Mild steel Gap 5–10 mm, 1.6 mm thickness 1.2 mm solid Ar80%/CO2 20 % – 38 A 16.8 V

3 Mechanically assisted droplet transfer and voltage waveform of the CMT process and the principle
of the droplet and electrode motion sequence. The droplet
New developments have enabled welding equipment such detachment occurs at almost zero current input. The two
as the power source, wire feeder, and the shielding gas flow main steps are arc phasing and short arc, described as follows
regulator to perform in synergy and obtain an optimised [39, 41–43]:
result as regards the welding dynamic characteristic. In the
Arcing phase: The arcing phase is distinguished by a
GMAW process, the wire feeder used to contribute to pro-
constant arc voltage corresponding to an initial high
viding the current and ensuring continuous speed of the
pulse of current which ignites the welding arc and heats
wire. Now use of the filler wire has advanced to a situation
both the workpiece and the wire electrode. The current
where it is fully integrated in the welding process. The
is then reduced to ensure that droplet detachment is not
overall motion of the wire is forward but it can be reversed
initiated but that a molten globule remains attached to
at a specific time to assist in the breaking of the molten
the end of the electrode and a weld pool is created.
metal during detachment into the molten pool. For this
Short circuit phase: In the short circuit phase, the
purpose, an inverter welding current source is used and the
electrode is fed into the weld pool, initiating an elec-
control algorithm is conjugated with the electrode wire
trical short circuit, marked by a reduction in arc voltage.
motion [9, 10, 40].
In conventional dip transfer, arcing results in a rapid
rise in current which melts the end of the electrode and
3.1 Cold metal transfer™ process
breaks the contact with the work surface [38, 44]. The
point of short circuit is sensed and the welding current
The cold metal transfer (CMT) welding process was
is reduced to a minimum, extinguishing the welding arc
patented by FORNIUS in 2004 and is based on a dip metal
and limiting the thermal energy transferred to the work
transfer mode. The system is equipped with a high-speed
piece. After a defined duration, the electrode is retracted
digital control, inverters and a processor that control all the
pinching the molten droplet into the weld pool and
process, for instance, the length of the arc, the current and
breaking the short circuit. The arc is then reignited and
the voltage. Whereas the material transfer in dip transfer
the cycle repeats.
welding is controlled electrically, the CMT process controls
material transfer via both the initiation and duration of the FORNIUS has continued to develop the CMT concept
short circuit and mechanically assisted methods. The main and an enhanced CMT version, called CMT Advanced, was
innovation is the reverse of the wire by a specialised alter- presented in 2009. The process integrated the retraction of
native current (AC) servomotor incorporated into the gun the electrode, measurement and control of the arc length,
that can oscillate the wire at frequencies up to 70 Hz at the and control of the polarity of the welding current. The
moment of the short circuit occurrence to assist with droplet change of polarity occurs during the short circuit phase
detachment. The metal can then be transferred to the molten and prevents possible negative effects as the circuit arc
pool with the retraction force and the electromagnetic force burns, for instance, instabilities related to the arc break of
of the welding pool [41]. Figure 10a and b show the current the process. The deposition rate can be adjusted by

Fig. 8 a Current and voltage of

MAG and SP—MAG method
and b corresponding droplet
transfer sequence [34]
664 Int J Adv Manuf Technol (2013) 67:655–674

Table 9 Effect of robot MAG

process welding parameters [37] Upper sheet Low sheet

Joint date (lap joint) Material S355 steel Material S355 steel
Thickness (mm) 1.3 Thickness (mm) 1.2
Weld data Current (A) 70 Stick out (mm) 9
Voltage (V) 17.4 Speed (m/min) 0.5

alternating the positive and negative process cycle. CMT Table 11 presents example data for some cases of welding
Advanced is said to decrease heat input, minimise distor- of different material grades using CMT. The result showed
tion, emit few fumes and be easy to perform. The process is good weldability o from 0.3 mm thickness and successful
offered in two variants; the first is characterised by a flow tests were also made with dissimilar materials such as alu-
with two positive and negative cycles of CMT, and the minium and steel. The results demonstrate the flexibility of
second is a combination of a negative phase and CMT of the the process and acceptable results were obtained for steel,
positive impulse phase [41, 45]. stainless steel and aluminium. Dissimilar metal joining of
A variant of CMT is pulsed CMT Advanced, the principle aluminium to zinc-coated steel sheet without cracking by the
of which is shown in Figs. 11 and 12, where the process CMT process in a lap joint is possible. The compound layer
flows with negative CMT phase and positive pulse phase. at the interface between steel and weld metal main consists
Compared with the conventional AC process, CMT of Fe2Al5 and FeAl3 phase [40, 42, 47–49].
Advanced separates the pulse arc from the negative current
phase. The process is characterised by a pulse cycle with 3.2 MicroMIG™ process
continuous feeding wire and a negatively pulsed CMT cycle
with a reversing electrode and an impulse arc phase with The MicroMIG™ process is developed by the SKS Welding
continuous wire feeding (Fig. 12). The metal transfer effects System Company and was launched at the Essen welding
of the pulsed cycle (positive electrode) after the negative and cutting 2009 expo. The process is characterised by a
phase of the current found in the conventional AC process supported mechanical molten metal transfer located between
do not apply because the molten metal formed during the the pulsed waveform. The manufacturer claims a high de-
negative CMT cycle is smoothly transferred in the following position rate without increasing the frequency, which results
short circuit. Furthermore, the molten metal is transferred in in less spatter and lower heat input. Figure 13 shows a
the pulsed cycle without a short circuit. Therefore, the typical waveform of the MicroMIG™ process [50]:
initialisation is of importance in controlling the transition
& Pulse sequence: A pulse sequence (3) (specific number
between two different cycles [41, 45, 46].
of pulse) is used to create the weld pool and set indi-
rectly the wire feed speed (deposition rate). The last
pulse creates a drop of molten wire at the wire end.
& Droplet transfer: (2) The wire is fed with low current
until contact with workpiece.
& Mechanically assisted droplet transfer: When the elec-
trode is in contact with the weld pool (5) the direction of
the wire feeder changes and the wire is retracted for a
pre-determined time (4).
& After re-ignition: The direction of the wire feeder is
again reversed (forward) and a new pulse sequence starts
after a short waiting time (1).
The MicroMIG process was realised with standard
components. These components are already in industrial
use worldwide. The torch system works with only one
main wire feeding unit, therefore, synchronisation prob-
lems, as in push–pull systems, are completely elimina-
ted. In addition, no wire buffer is required. The related
Fig. 9 Current waveform of metal transfer stabilisation welding pro- consumables (liner, driver rolls, centre guides) are avail-
cess [34, 42] able for aluminium wires with a diameter ranging from
Int J Adv Manuf Technol (2013) 67:655–674 665

Table 10 Example welding parameters with the metal transfer stabilisation process

References Material Groove Wire Shielding gas Wire speed Welding speed Current Volt Gas flow
(cm/min) (cm/min) rate

[39] AISI304L 2.0 mm ER308; 1.0 mm 98 % Ar+2 % O2 450 70 100 A 15.0 V 15 l/min
AISI304L 1.0 mm Lap joint ER308; 1.0 mm 98 % Ar+2 % O2 410 100 100 A 14.0 V /
AISI304L 0.6 mm Lap joint ER308; 1.0 mm 98 % Ar+2 % O2 530 300 115 A 14.0 V /

0.8 to 1.6 mm. The process is designed for robot be designed to provide a range of heat inputs for a given
applications [50]. wire feed speed, thus allowing optimization of the travel
Table 12 presents example parameters for an experiment speed for different weld deposit size applications [52, 54].
with X5CrNi18-10. The MicroMIG process was able to Steel and aluminium alloy are the most widely used metals
achieve acceptable mechanical properties and visual appear- in various industries. When joining steel to an aluminium
ance, with few defects [51]. alloy, it is not easy to obtain good welding quality because
their physical characteristics greatly differ. In particular, the
intermetallic compound layer that appears between the dis-
4 Variable polarity GMAW or AC-MIG transfer process similar welding parts makes them brittle, thereby resulting in
significantly low strength and deformation. In order to mini-
Variable polarity (VP)-GMAW or AC GMAW is a recent mise the brittleness of the intermetallic compound layer, its
pulse welding process [52, 53]. The electrode positive back- thickness must be 10 μm or less [55, 56].
ground period current switches to maintain the arc at a low In a study conducted by JP Hyoung et al., steel (SPRC 440)
current. The electrode positive peak period is used to trans- was weld brazed to aluminium alloy (6 K21) using AC-pulsed
fer the droplets by using a high-current pulse that squeezes MIG welding, which alternates between DC electrode-
the droplet off the electrode tip. The drops transfer across positive and DC electrode-negative based on the EN ratio.
the arc into the weld pool. The VP-GMAW waveform can The resulting weld characteristics were evaluated [57].
The study drew the conclusions from experiments on the
joining of SPRC 440 steel and 6 K21 aluminium alloy by
AC pulse MIG welding that based on the SEM and EDS
analyses, a thin intermetallic compound layer was obtained
due to lower heat input to the base metal as the EN ratio
increased. In addition, the analysis of the tensile strength test
in relation to changes in the EN ratio, it was observed that as
the EN ratio increased, the tensile strength value improved
with good gap bridging ability [57].

Fig. 11 Variation of welding current (IS), welding voltage (US), and

Fig. 10 a Cold metal transfer tension and current wave curve and b wire feed speed (Wfs) in CMT for dependence pulse CMT Advanced in
CMT droplet and electrode motion sequence [40] the EP and EN phases [41]
666 Int J Adv Manuf Technol (2013) 67:655–674

Fig. 13 Current waveform of the MicroMIG SKS Welding System

[48, 50]

performance from robotic to manual application by improv-

ing the stability of the arc at low values of welding current.
Fig. 12 Process course, two positive (EP) and negative (EN) CMT The previous version was limited to aluminium, mild steel
Advanced cycles [39, 41] but new welding equipment has included structural steel
[53, 59]. The increase of the welding current and the load
The polarity switches from electrode positive (EP) to EN (P0300 A at 80 %) gives additional advantages [54, 60].
just after the pulse peak current and a cathode spot is formed The EN polarity ratio has a significant effect on wire
on the surface of the retained molten metal near the slender melting speed in AC-pulsed MIG welding. It has been found
wire tip. Under the effects of the random motions and reaction that at 150 A of mean welding current, the melting speed of
forces of the cathode spot, the retained molten metal is pulv- a wire with 40 % EN ratio is 60 % higher than that with a
erised to form tiny spatters flying out of the arc area [58]. 0 % EN ratio (DCEP) in DC-pulsed welding. In addition to
the high deposition rate, it was observed that low amperage
4.1 AC-MIG™ (OTC-Daihen) process results in a decrease in heat input as the EN ratio grows. DW
300 comprises software with an algorithm capable of vary-
The AC MIG welding process from OTC-Daihen Japanese ing the EN ratio up to 80 % [61].
Company, presented in 2008, uses the digital AC/MIG Pulse Figure 14 is an illustration of a typical AC MIG/MAG
Inverter DW300 to perform welding operations with low waveform. The first waveform (a) is characterised with a
heat input. The new version is a completely digitally con- conventional EN ratio limited to 30 %, adequate for alumi-
trolled process based on the previous AC-MIG200, which nium welding. In the second AC waveform (b), the EN
was limited in its application. The innovation extends the component is divided in two areas: the base current and

Table 11 Example welding parameters with the CMT process

References Material Groove Wire Shielding gas Wire Welding Peak Volt (V) Gas flow
speed speed Current rate

[42] Zinc-coated Dissimilar lap Al-Si 1.2 mm Argon – – – – 15 l/min

steel (0.6 mm) joint
Al 1060
(1 mm)
[47] AA 6111 Bead on a 1–2 mm 4043 Pure argon – 1.0 m/min – – –
Mix CMT plate 3 mm
[40] Ni–Cr Butt joint 4316 1.0 mm 97.5 % Ar+2.5 % – – – – –
Stainless 0.3–2 mm CO2
steel
AlMg3 Butt joint AlSi5; 1.2 mm Pure argon – 2.0 m/min – – –
1.0 mm
[48] Hot-dip Lap joint; Al-Si 1.2 mm Argon 3.9 m/min 762 mm/min 66 A 11.8 15 l/min
galvanised 1 mm 5.4 m/min 913 mm/min
steel and Al
1060
[49] DC 0.4 Lap joint; Autrod 1251; Ar 80 % + / 15–30 mm/s / 81–89 A
0.8 mm 1 mm CO2 20 % CTWD010–
18 mm
Int J Adv Manuf Technol (2013) 67:655–674 667

Table 12 Example welding parameters with MicroMIG

References Material Groove Wire Shielding gas Welding speed Gas flow rate
(cm/min) (l/min)

[51] 1,4301 (X5CrNi18-10) Lap joint; 0.8 mm 1,4370; 1.0 mm 98 % Ar, 2 % CO2 100 14
1,4301 (X5CrNi18-10) T joint; 1.5 mm 1,4370; 1.0 mm 98 % Ar, 2 % CO2 95 14

the pulse current. The base current is applied to sustain the the tip of the electrode during the negative phase that directs
arc at the time of the changing of voltage polarity and the heat into the wire and cools the weld pool [62].
pulse part is to control the penetration [58]. The CP process consists of two different concepts. The
The results of two experiments are presented in Table 13. first, presented in Fig. 15, combines the current and voltage
The materials are Japan low alloy steel (SPCC) and alumi- waveform and can be described as follows [62, 63]:
nium alloy (A5052). Welds joints were performed on a bead
& Arc burning period (1): The current and voltage are in
on plate of 3.2 and 3 mm to evaluate the penetration relative
the required negative pulse for a certain period time. The
to the EN ratio. The results showed lower penetration as the
wire is moving toward the workpiece
ratio increases and less risk of burn through [57, 58].
& Short circuiting period (2) and (3): The current and
voltage are suddenly increased to a level required to
4.2 Cold process™
start the droplet transfer
& Pinching period (4): The wire short with the work piece
The German company, Cloos, in 2002, successfully devel-
and the current is increases sharply to allow the pinch
oped the first variable polarity MIG/MAG welding GLC
effect and necking for the droplet transfer into the weld
353 QUINTO cold process (CP) [58, 62]. The DC positive
pool. The voltage is reduced to about zero, just as in
polarity of the electrode in pulse MIG/MAG provides a
short circuiting transfer mode
stable arc and better penetration; however, it is likely to
& Droplet transfer period (5): There is a sudden decrease
generate undercut, burn-through on sheet metal and other
in the current and voltage to permit smooth separation of
defects. On the other hand, negative DC MIG/MAG weld-
the molten metal to the weld pool and re-ignition of the
ing generates an unstable arc, difficult droplet transfer, and
arc
shallow penetration. The AC GMAW that Cloos developed
integrates the advantages of both previous applications [62]. It can be observed that the CP process combines the
GLC 353 QUINTO CP uses a unique current waveform. advantages of the AC pulse and dip transfer modes. The
By adjusting the parameters of the negative base value of the burning arc occurs in EN polarity, which results in an
heat input, the welding process is carefully controlled to increase in the melting rate. In addition, the short arc period
ensure the best welding results. In the actual welding, considerably reduces heat input in the workpiece compared
increasing the base value of negative time can significantly to the conventional short arc process.
improve the deposition rate of the wire, improve welding The second concept is a variable polarity GMAW pro-
speed, and reduce the heat input [62]. cess. Figure 16 presents a typical current and voltage wave-
CP consists of a special current waveform designed to fill form of the process. The concept is an innovation in the
the gap and ensure good coverage and excellent welding domain of AC MIG/MAG pulse welding. The curve bene-
results. The positive polarity ensures the cleaning stage and fits from the latest research into possible improvements in
the heat input of the base metal by control of the pulse phase the shape of the variable polarity waveform and can be
to release the droplet to the base metal. The arc surrounds described as follows:

Fig. 14 Modified current

waveforms in DW 300 with EN
ratio up to 30 % (a) and
above 30 % (b) [58]
668 Int J Adv Manuf Technol (2013) 67:655–674

Table 13 Example welding parameters with the AC-MIG process

References Material Groove Wire (in) Shielding gas Wire speed Current (A) Volt Gas flow rate
(cm/min) (l/min)

[58] SPCC Bead on plate; 3.2 mm ER70s-G; 1.2 mm 80 % Ar+20 %CO2 700 165–210 24.5–26.5 V 20
A5052 Bead on plate; 3 mm ER5356; 1.2 mm 100 % Ar 600 65–98 15.6–17.6 V 20

& Transition from EP to EN (1): the EP is kept at low benefits of spray transfer. GMAW-P is characterised by
current level to ensure smooth transition to the EN pulsing of the current between the low-level background
polarity and avoid tiny spatter current and the high-level peak current in such a way that
& Arc burning period at EN (2) and (3): the arc shape the mean current is always below the threshold level of
increase the melting of the electrode, the penetration spray transfer. The purpose of the background current is to
and maintain EN period to keep a constant arc length maintain the arc, whereas the peak currents are long enough
& Pinching period (4): Peak positive pulse for pinch effect to ensure detachment of the molten droplet [65].
and start necking for droplet transfer The transition current zone between the globular and the
& Droplet transfer period (5): the current is reduced at spray mode is of great importance in the GMAW-P process.
required level to prepare the alternative change to EN It limits the highest current for globular transfer and the
lowest for spray transfer and thus determines the working
Table 14 presents examples of welding parameters with
conditions of the process [66, 67]. The GMAW-P process
the CP process. In a manual test on DC01 steel (2 mm thick
advances the concept of combined or hybrid metal transfer
low alloy steel), the welding process was found to be faster
mode. In normal transfer mode the dissimilar modes, e.g.
than the same weld with the semi-automatic conventional
free flight transfer and bridging transfer modes occur ran-
process. A 0.7-mm thick stainless steel was welded with CP
domly, however in combined or hybrid metal transfer the
and completion of the weld was faster than the same weld
relevant mode is attained intentionally and in a controlled
done with a conventional semi-automatic process and about
manner using features of advanced power sources [68]. The
as fast as the same semi-automatic pulse welding process.
emphasised is in combination of pulse spray and short arc
The welding tests for 4-mm thick S700MC and 4-mm thick
metal transfer mode.
AISI304L were not successful showing that CP is not suit-
The classic methods of arc welding (TIG, MIG), used to
able for this thickness [63, 64].
join aluminium alloy parts of small thickness, do not pro-
vide the required quality of weld joints, mainly because of
the difficulties in maintaining a stable process with low
5 Pulse spray/short circuit metal transfer
welding current, and cause welding unconformities, such
as decreased mechanical properties in the joint and a rela-
An alternative transfer technique, GMAW-P, was invented
tively large heat-affected zone (HAZ), melting, partial
in the mid-1960s. This mode of metal transfer overcomes
the drawbacks of the globular mode while achieving the

Fig. 15 Metal transfer process and current and voltage waveforms of Fig. 16 Pulse droplet transition and current and voltage waveforms of
non-pulsed cold welding [79] the cold-welding process [79]
Int J Adv Manuf Technol (2013) 67:655–674 669

Table 14 Example welding parameters with the cold process

References Material Groove Wire Wire speed Welding speed Current (A) Volt
(m/min) (cm/min)

[64] DC01 2 mm – – – – –
AISI 304 L 0.7 mm – – – – –
Low alloy steel Lap joint 1.5 and 4.17 mm – 2.25 – – –
Al Lap joint (gap 1.5 mm) AlSi5; 1.6 mm 9.0 15 – –
[63] CuSi3 Lap joint; 1.0 mm 1.2 mm 4.5 80 132–135 16.0–16.5 V

melting, hot cracks in high-strength aluminium alloys with a possible to control the welding process much more precisely
high content of alloying elements, oxide inclusions and and to change the welding current very quickly. However, it
porosity, as well as weld shape inconsistencies (especially is very different today [71].
for the MIG method) [69].
An investigation comparing the effects of the GMAW 5.1 Pulse/pulse™ arc process
and the GMAW-P welding processes on microstructure,
hardness, tensile and impact strength of AISI 1030 steel The company ESAB developed an enhancement of GMAW-
joints fabricated by ASP316L austenitic stainless steel filler P in 2003. The technology is an improvement permitting
metal showed that the GMAW-P joints of AISI 1030 steel more accurate control of the waveform and thus enabled the
couples exhibit less grain growth when compared to company’s engineers to design a multi-process power
GMAW joints in the HAZ. The highest impact strength source called ARISTO™ Superpulse. The concept, known
value was measured in the sample performed with the as pulse/pulse (double pulse) and pulse/spray, was already
GMAW-P technique. The grain growth because of the high available from other manufacturers but the innovation by
heat input occurring in the GMAW technique causes a ESAB is a pulse/short arc, which aims is to completely
decrease in the impact strength values of the joint. The control the heat input and arc for sheet thin metal. The
low heat input in the GMAW-P and the fine grains occurring pulse/pulse arc mode is used for welding medium thickness
in the weld metal due to the rapid solidification and shaped and thin materials. Aristo Superpulse is fundamentally a
as small and slender structured, increased the hardness value software solution included in the operator pendant [72].
[70]. Figure 17a illustrates the pulse/pulse process technology.
The GMAW of thin aluminium was complicated by the A motivation behind the approach was to provide a GMAW
fact that short circuiting arc transfer (short arc) is not rec- solution for aluminium welding that made the process less
ommended for the GMAW of aluminium alloys. Spray difficult than standard pulse and therefore required less
transfer is always recommended for welding aluminium. In operational skill. Unlike standard pulse welding, pulse/pulse
the past, it was impossible to weld thin aluminium of uses a sequence of varying pulse wave shapes to create a
1.6 mm thickness because even with the smallest diameter bead shape and appearance similar to the GTAW process. It
aluminium wire available for the GMAW, 0.8 mm, the utilises low amperage in the primary phase for heat reduc-
welding current had to be above 85 A to get spray transfer. tion and higher amperage in the second phase for enhanced
This was just too much current to weld thin materials, and so penetration [73–75].
the GMAW of thin aluminium simply was not performed in Figure 17b presents the spray arc/pulse arc process,
production. Pulsed GMAW was developed and made it which was initially developed for positional welding of

Fig. 17 ESAB Aristo

SuperPulse waveforms: a pulse/
pulse, b spray/pulse, c pulse/
short arc [73]
670 Int J Adv Manuf Technol (2013) 67:655–674

Table 15 Example welding

parameters with the pulse/dip Material type Stainless steel Travel speed
or spray process [78]
Material thickness 0.8 mm Primary wire feed speed (WFS) 2.0 m/min
Joint type V. Butt Secondary wire feed speed (WFS) 1.2 m/min
Welding position PA
Wire type 16.32 (316 LSi) Primary voltage 21.8 V
Wire diameter 1.0 mm
Gas Type 97.5 Ar; 2.5CO2 Secondary voltage 14.8 (+0.8) V
Primary phase Pulse
Secondary phase Dip/spray Primary time 0.30 s
Pr. phase synrgic On
Sec phase Synrgic On Secondary time 0.10 s

thick materials. The welding speed and even penetration are 6 Comparisons of new arc welding processes
provided during the spray arc phase, whereas heat input is and conventional welding processes
reduced during pulse phase. This arc welding process mode
enables vertical-up welding of aluminium without any wav- Table 17 presents a comparison of some key features of new
ing motion. It utilises spray arc transfer in the primary phase arc welding and conventional processes. The new processes
for enhanced penetration and pulse arc in the secondary listed in this table belong to the GMAW welding process
phase, which serves to cool the weld pool for less heat group. It should also be noted that the comparison does not
transfer to the base material and less distortion. Pulsing in distinguish between manual, semi-automatic and robotised
the second phase also allows spray type transfer to be processes, and focuses on the waveform ability to increase
achieved in all positions of welding [73–75]. the droplet transfer with low heat input. The comparison is
Figure 17c depicts the pulse arc/short arc process, which based on the results of both academic studies and informa-
was developed for very thin aluminium and stainless steel. It tion provided by the suppliers of the power sources. It can
utilises pulse in the primary phase and a short arc in the be seen that a significant amount of the information is from
second phase with very low heat input and a GTAW bead manufacturers. This is because limited research has been
appearance. It can be used in all positions of welding and published presenting comparisons of new welding applica-
has low sensitivity to variations in root gap. The process can tions; the main raison being the investment required to
also be used for root runs from one side in thicker materials conduct such comparative research.
without the need for backing. A variety of arc welding process concepts has been
Tables 15 and 16 present welding parameters of stainless suggested during the last decades but interest in scientific
steel and AlMg, respectively, as given by the manufacturer research of such processes is still low, although some of
for the combined pulse and dip or spray transfer mode them, such as WiseRoot, STT, and CMT, have been studied
process. An analysis by [74] of welding process speed with and scientific publications are available. These welding
combined pulse investigated the distortion resulting when processes have demonstrated improvements in terms of heat
welding aluminium. The results showed that the process input reduction, improved speed and productivity, and an
reduces heat input without compromising productivity. increased range of material weldability [39, 42, 47, 76].

Table 16 Example welding

parameters with the pulse/dip or Material type AlMg Travel speed
spray process [78]
Material thickness 1.5 mm Primary wire feed speed (WFS) 3.0 m/min
Joint type Butt Secondary wire feed speed (WFS) 1.1 m/min
Welding position PA, PC
Wire type 18.15(5356) Primary voltage 22.8 (+10)V
Wire diameter 1.2 mm
Gas type Ar Secondary voltage 12.0 (+3.6)V
Primary phase Pulse
Secondary phase Dip/spray Primary time 0.2 s
Pr. phase synrgic On
Sec phase synrgic On Secondary time 0.1 s
Table 17 Comparison of low heat input welding processes for thin sheet metal [13–79]

Group Features Welding speed vs Thermal Material and thickness Gap -bridging and Productivity
processes MIG/MAG input position (mm)
Steel (≥mm) Stainless steel Al (≥mm) Mixed
(≥mm) joint

Advanced WiseRoot 10 % faster 10–15 % less 0.6 Yes – No 6 Good Different position
Int J Adv Manuf Technol (2013) 67:655–674

controlled STT High welding speed Lower than TIG 0.9 Yes 0.9 Possible 5a High productivity
RMD Increase 2 or 3 times Reduce heat inputa 3.17 or less Yes 3.1 or less –b 4.7 High productivity for root
fastera pass
Cold Arc Can improve Minimised 0.3 Yes 1.3 Yes + Possiblea All positiona
Cold MIG Increase Minimised 0.6 Yes 0.6 Yesa Can+ All position,
IAC 15 % faster Reduce heat inputa 0.6a Programme 0.6a –b + Possiblea Increase productivitya
include
SP-MAG Faster Lower Tested on 1.2 Yes –b –a Possible Increase productivity
CBT Faster Reduce 0.8 Yes No No 1.4 ++
Mechanically CMT 50 % Slightly twice 30 % 0.3 Yes 0.3 Yes 2.5 ++
assisted fastera
CMT Advanced 50 % Slightly twice 30 % 0.3 Yes 0.3 Yes 2.5 +++
fastera
Micro MIG Same as Lessa 0.6 Yes 0.6 –b No exp ++
AC-MIG AC-MIG + Increased −Reduction 30–40 %a Thinner Yes Less than 0.8a No expb 2 +++ Good because of
modified melting rate
CP ++ Increased Reduction − − 0.5 Yes 0.8 No 2 +++
Hybrid metal Pulse/short arc ++ Increased Reduce − − 0.6 Yes 0.6 Yes Nob High productivity root pass
transfer
Conventional Short circuit Slower Moderately higher 0.6 − − No Difficult Thin sheet all position
MIG/MAG pulse Moderately slower Higher 0.6 Yes Yes No Difficult Thin and medium

− Decrease of feature, + increase in feature

a
Indication from the manufacture
b
No information
671
672 Int J Adv Manuf Technol (2013) 67:655–674

7 Conclusions and summary laboratories with the same settings. New transfer modes
such as the combined pulse, short-circuiting and mechanised
The aim of this study was to investigate new innovations in droplet transfer implemented by innovative arc welding
terms of novel concepts and significant improvements. The concepts should be introduced in new classification of metal
investigation leads to the following conclusions. transfer modes. This work can be used to further study
Arc welding processes have developed considerably with industrial development and application of new welding
new techniques and applications being implemented. procedures.
Principal aims have been to reduce the heat input, suppress
the harmful spatter phenomenon, and increase the flexibility
of welding processes. Usability of the processes discussed in References
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