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Feature: High efficiency welding of aluminum alloys

Aluminum arc welder with digital control of the Technology Part two windows *, . Kim Yu Chan * Kim kinds too ** * BEST F.A Institute of Technology Engineering, Korea Maritime University institutions ** Technology on Arc Welding Machine of Aluminum by Digital Control

, Chang-Je LEE* , Yu-Chan KIM* and Jong-Do KIM**

*R&D Institute, BEST F.A, Changwon 641-290, Korea **Division of Marine Engineering, Korea Maritime University, Busan 606-791, Korea Corresponding author : lab@bestfa.co.kr

Abstracts
Recently, welding technology of nonferrous metals which were difficult to implement by arc welder has become available through digitalization of arc welding machine. Among them, the welding quality improvement of aluminum welding is very noticeable. These results increase the arc stability by controlling arc current and voltage waveform precisely, and control wire feed speed by synchronizing with arc current which the feed rate of filler wire is controlled by a precise motor control of servomotor and not by a simple constant speed feeding. Not only through the hardware digitalization of arc welding machine but also through advance of software of arc welding, it became possible to implement a certain level of welding quality by a simple operation. These led to CMT welding process implementation which requires low heat input than current arc welding and highly increased the applicability of the aluminum welding. Key Words : Aluminum, Digital, Arc stability, Inverter, Synergic line, CMT

1. Introduction
In recent years, the depletion of energy resources and environmental issues such as global warming, sustainable development and launch of the product line is followed . In order to solve this problem using reusable materials , or for increasing the energy efficiency of various regulations and conventions around the world are actively discussed and running . These issues are receiving the most attention in the widely known and used is aluminum . In particular, a reusable lightweight aluminum as a material has been used in various fields from a long time ago that future consumption is expected to increase 1 ). However, processing of aluminum are committed to reducing energy use, the energy is higher than the actual problem and the difficulty of processing application as there are many difficulties . Aluminum in the manufacture of the welding process for aluminum Journal of KWJS Vol.31 No.1(2013) pp26-32 http://dx.doi.org/10.5781/KWJS.2013.31.1.26

Work process is the most prestigious high process . In general, the strength of pure aluminum is very weak, the material used in the form of alloys of aluminum alloy , which is known to cause many problems when welding characteristics . Therefore , a precision aluminum welding is essential for the control of welding condition 2 ). Especially during the welding of aluminum alloy and heomping spatter beads, The deterioration of the weld HAZ and various defects such as cracks and pores appear very easy to select the welding conditions are very difficult and the management of the welding process must be very carefully maintained . However, these conventional arc welder working process is very difficult to precisely control the welding defects and defect causing a lot of aluminum welding , so a skilled worker and a very strict process management necessarily was required. Because of this, the rising cost of production slowdowns and the aluminum material to be used as a general-purpose point was difficult . However, as recently digitized welder welding conditions

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Were able to precisely control . The digitization of these various defects that occur during aluminum welding is controlled very effectively . Thus, in this newspaper , the digital welding machine aluminum welding technique is to describe 3-5 ). Two . Digital welding machine is Werdersee 2.1 Features of inverter welding machine Since the 1980s introduced the inverter (inverter) welding the existing thyristor (thyristor) Unlike welding does not change merely exchanges one car rectified into DC to DC switching device by using one again and again after a high frequency AC to DC conversion convert 6-8 ). Fig. 1 of the inverter transformer secondary rectification according to the frequency that shows the changes in (a) look at a graph of the frequency increases, the secondary rectifier transformer , which can be determined that the size of the reduced accordingly inverter welder secondary rectification frequency increases than conventional welding is being made very small and light . And (b) shown in the higher the frequency of the waveform conversion ripple pattern (ripple patten) by reducing the welding

Thereby stabilize the current , such as welding spatter, weld defects caused by instability of the current can be suppressed. 2.2 Digitization of inverter welding machine In recent years, the current DC arc welder to convert simply does not stop for precise welding control Fig. 2 and As DSP (digital signal processor) is built . Digitized welding inverter welding machine is equipped with a dedicated software such as welding current and voltage in real-time feedback (feedback) to accept the change of welding conditions and symptoms treated with DSP and feeding the inverter optimal control devices, etc. should . Thus, reproducibility and quality welding high welding was able to look forward to . 2.3 Control of welding conditions Shown as a digitized welding biggest change is that you can get a very stable arc . Fig. Way as in the more than three digitally controlled thyristor inverter
Remote control Wire drive

Serial

Data bus

RS 485 HOST

20

Control monitoring

A D

Digital actual value

DSP
Process control

INVERTER

V (dm)

Actual value (U/I)

Fig. 2 A communications system of digital welding machine

1

Type
50 100k f

(Hz)

(a) Change of transformer volume as a function of transform frequency Data

Thyristor Inverter

20kHz 100 kHz

Welding condition

Waveform t (b) Ripple of waveform with frequency

Fig. 1 Change of transformer volume and waveform on applying digital inverter 31 1, 2013 2

Fig. 3 Welding condition by difference of power source of thyristor and inverter typea

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I I
crit

I
mean

t I
3 2 1 4

Fig. 6 Waveform in pulse welding

t

Fig. 4 Controllable short circuit transfer by digital inverter power source Way more stable state of the arc and the weld can see that . This transition mode (transfer mode) that control the look at the difference in calligraphy , especially the implementation of paragraphs that are typically used when welding aluminum (short circuit transfer) is very effective at . In general, a short paragraph yihaengsi (short circuit) in the event of a sharp increase of the peak current caused by spatter together remarkably , the Fig. As four vertical voltage direct current after a period without zooming in section keeps constant after the peak short- interval boost from the end Arc reliable digital control is to occur . These differences are shown in Fig. 5 shows the existing implementation of the short- time arc from the current value of the peak period , as well as the momentary increase in short- term due to fire, steady flow of current in the arc becomes unstable and spatter molten pool occurs. So regardless of digitally controlled short-circuit current waveform while maintaining a constant peak current due to short-circuit control , because the relatively low stability of the arc and little spatter shorted
Type

Balsae not . Aluminum welding techniques commonly used in the following paragraph, the implementation is the pulse welding process . Pulse welding is shown in Fig. 6 as the base current flows in pulses that occur in the state by the implementation capacity in the region is how to weld . This method only when the pulse applied to the base metal heat input , so the average current is low, mainly applicable for welding sheet metal and aluminum welding heat input management is important for the base current must be controlled to a level of about 30A can guarantee a stable arc . However, only one volume of one tteolguneun pulse is very difficult . Because molten weld pool and the arc is constantly moving to just simply to generate a pulse waveform is kept constant in one volume per pulse mothayeo one can not cause a transition can not achieve the desired goal . However, the digital welding arc and molten pool is affected by the current to the DSP processing , regardless of the welding conditions to form a constant current pulse feed . Especially when welding aluminum to maintain a low base current to the arc length is always important to maintain a constant , it rapidly to the voltage and synchronous transmission by wire transfer by controlling the arc length changes dramatically depending on the song quickly becoming rapidly controlled allows us to maintain the current low base . Fig. 7 as a digital welder only one volume per pulse to form a highspeed camera shows the picture and waveform.

2.4
Data
Conventional Digital

Short circuit transfer

Waveform

Fig. 5 Short circuit transfer by difference of power source of conventional and digital type

One of the important things when welding aluminum welding is the beginning and the end. This is the final appearance of the product is produced, because the quality is directly related to, in particular due to the high thermal conductivity and low Melting point of aluminum on the beginning and the end of the weld spatter and porosity leads to a lot. One way to control it, as SFI (spatter free ignition) technique. The MIG welder is SFI D teolhwa technique is applied to the arc start. In general, by a short-circuit arc start at about as high as 500 ~ 700A large amount of current flows momentarily Journal of KWJS, Vol. 31, No. 1, February, 2013

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Start

Arc boost

Short circuit

Rewind wire

Separating droplet Droplet

Arc ignition

Start welding

Fig. 7 Controlled droplet by digital welding machine

Fig. 8 Arc ignition depending on spatter free ignition

Will cause spatter . Realize bead appearance due to an influence on the quality of the product you are creating a lot of bad . This is more noticeable the larger the diameter of welding wire to negative welding torch consumable parts jimyeo shorten product life . In order to control the welding current and wire feeding the need to control movement . Fig. As shown in the first eight starts during welding wire for lighting falling short circuit occurs and the base metal welding current by sensing the voltage to prevent a sudden rise at the same time makes the wire back and reverse . When you reach a certain distance the wire after about 20 ~ 50A for the low current arc ignition in the welding is carried out after that . These arc welding aluminum lighting close to 100% of lighting shows reproducibility . Conventional aluminum welding due to the demanding welding conditions require excellent skills were professional welders . However, the digital welding machine for aluminum as a separate program by embedding a simple operation alone was possible to weld aluminum . Fig. 9 is a typical MIG aluminum only start the program . As shown in the figure, the thermal conductivity of aluminum, the high starting current by considering Fig. 10 and Defective parts without welding arc start , as can be formed. In addition, the current arc in the end by keeping 50% of the current crater (crate) is to be filled portion .

IS 150 %

100 %

50% Starting current 0 Fig. 9 Exclusive start program for MIG aluminium welding Elegant aluminum welding seams or pores get the weld quality based on the occurrence of a concern if the program used synchrotron pulse (synchro-pulse) is Synchro pulses to the DSP Equipped with a digital power source synchronized with wire feeding device is applied to welding. The best feature of this program, the pulse current and the welding wire transfer will synchronize rapidly. Fig. In section 11, as shown in the welding current and the welding wire transfer rapidly (dFd) is synchronized to the pulse welding is As a result, the welding current is applied to the wires and move forward quickly to non-authorized at the time of transfer matrix are committed to neutchueo welding current Crater-fill current t

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Type Data

Conventional

Start program

Bead appearance

Cross section

Fig. 10 Comparison of conventional start and start program

E n d c r a t e r

Fig. 13 Radiograph without porosity in 4-layers wilding of Al6082 of thickness 12mm CMT welding 3.1 CMT principles of MIG welding heat input as a way to minimize the short arc with the implementation of paragraph (short arc) is used, which is a short paragraph at the problems of the arc by arc discharge of high current occurs as expected easy to control the heat input is that. As a way to overcome the CMT (cold metal transfer) the Has been developed. CMT also basically the biggest difference between a short arc and is shown in Fig. At paragraph 14, as shown in the reverse wire to force a shutdown and short-circuit arc between the base metal and wires Boost (boost) makes. Maintaining a low voltage, shortcircuit and short-circuit in the region according to the flow of current is controlled. This high current due to the occurrence of the arc occurs only between the base metal and wire, so high short-circuit current flows from the base metal, unlike the short arc heat input is very low, 9, 10).

Current/vD

Frequency

Arl dFd

dFd Start current vD(m/min)

time

Fig. 11 Synchro-pulse program for aluminium welding

Fig. 12 Bead appearance of aluminium weldment by using synchro-pulse program

Fig. 12 .

. Fig. 13 Al6082 4 . .
30 Fig. 14 Change of current, voltage and feeding rate in welding of CMT process

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3.2
CMT arc welding on a variety of structures that can be applied to opened the possibility , Fig. 15 As shown in the twenty-two kinds CMT welding thick aluminum lap shows an example of . As in the picture of the plate and lap welding aluminum bakpanjae and the difference in thickness is very difficult to control the heat input of the process was applied to the other high-priced . CMT Performance of the low heat input , however, the implementation of this paragraph I under conditions that maximized while minimizing the heat input to the base metal was able to weld . Fig. 16 shows the thickness according to the CMT welding . (a) the overlap in a 3mm thick aluminum plate is welded to the same conditions approximately 50% of the pulse MIG welding can be faster . And (b) of the 0.3mm aluminum plate welded to the butt of MIG welding can be welded sheet shows the limits of good . This excellent welding performance, Fig. Already as 17 helicopters and three layers of the crust of the bonding flange welding and welding of aluminum itself is being applied to . Four . Conclusion Until recently, precision welding with arc welder said that there is a limit wateuna , arc welder as digitized more precise and highly reproducible been able to control . Thus, until now, was not applicable and that the ultrathin sheet welding heat input was possible , improve the quality of aluminum welding
(b) Laminated joint welding of 3 sheet joint(pipe, flange, coupling) for fuel supply line

(a) Overhead butt welding without backing of 0.8mm Aluminium for helicopter out skin

(c) B-pillar to roof joint of premium sedans and spots cars

Fig. 15 Overlap welding of 0.8 and 4.0mm aluminium sheet by CMT

Fig. 17 Application example of aluminium welding by using CMT Neunde breakthrough role was The digitized materials by arc welder can be equipped with dedicated software excellent skills in the field and the lack of a welder welding personnel in the production process in a short period of beginner to advanced personnel training can do to stabilize the welding quality in record time advantage have.

(a) Thickness 3mm

(b) Thickness 0.3mm

Fig. 16 Welding of thickness 3 and 0.3mm aluminium sheet by CMT

In particular, non-ferrous metals and alloys such as aluminum welding at high welding speed, excellent welding quality, and to keep going forward is expected to apply to various fields.

1. H.T. Kim and S.C. Kil : Trends of Welding Tech-nologies (Aluminium Structure), Journal of KWJS,

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22-4(2004), 29-34 (in Korean) 2. H.C. Yoo and H.T. Kim : Recent Technological Tendency of Joining for Light Aluminium Alloy, Journal of KWJS, 29-3 (2004), 4-13 (in Korean) 3. D.H. Woo, Y.M. Chae, S.W. Han, G.H. Choe, G.S. Han and G.W. Ahn : Design of Digital Controller for Thyristor Controlled Arc Welding Machine, Journal of KIPE, 3-2 (1998), 92-98 (in Korean) 4. H.K. Kim and B.D. Park:Development of Digital DC-Arc Welding Machine, Journal of KSOE, 20-6 (2006), 18-23 (in Korean) 5. S. Yamane : Current and Trend of Digital Power Welding Sources, Journal of Japan Light Metal Welding and Construction, 43-4(2005), 1-5 6. K.S. Harn : Characteristics of Inverter Type Arc Welding Power Source, Journal of KWS, 11-2 (1993), 21-26 (in Korean)

7. Y.M Chae, J.S. Gho, J.W. Kim, S.Y. Lee, H.R. Choi and G.H. Choe : A Study on Current Waveform Control and Performance Improvement for Inverter Arc Welding Machine, Journal of KIPE, 4-2(1999), 129-137 (in Korean) 8. Tosiro Uezono and Hongjun Tong : Application to MIG Welding Using Welding Power Source Equipped with Digital Filtering Process, Journal of Japan Welding Society, 76-4(2007), 243-246 9. J. Feng, H. Zhang and P. He : The CMT Short-circuiting Metal Transfer Process and Its Use in Thin Aluminium Sheet Welding, Material & design, 305(2009), 1850-1852 10. K. Furukawa : New CMT Arc Welding Process welding of steel to aluminium dissimilar metals and welding of super-thin aluminum sheets, Welding international, 20-6(2006), 440-445

1977 BEST F.A , , e-mail : lab@bestfa.co.kr 1961 BEST F.A , e-mail : jimmy@bestfa.co.kr

1963 , , e-mail : jdkim@hhu.ac.kr

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Journal of KWJS, Vol. 31, No. 1, February, 2013