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Statistical analysis of multiple wire welding processes
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INTERNATIONAL INSTITUTE OF WELDINGINTERNATIONAL INSTITUTE OF WELDINGSlovenian DelegationSlovenian Delegation
Doc. 212-997-01
STATISTICAL ANALYSIS OF MULTIPLE-STATISTICAL ANALYSIS OF MULTIPLE-WIRE WELDING PROCESSESWIRE WELDING PROCESSES
by Marjan Suban and Janez Tušekby Marjan Suban and Janez Tušek
FOR MORE INFO VISITFOR MORE INFO VISIT http://sites.google.com/site/chaosweld/http://sites.google.com/site/chaosweld/
My web page: http://www2.arnes.si/~msuban1/
INTRODUCTIONINTRODUCTION
Analysis ofarc light
Analysis ofarc noise
Analysis of welding currentand welding voltage
WELDINGWELDING
Analysis ofacoustic emission
from material
Analysis ofhigh-speed
camera recordings
MAG/MIGSAW
SUBMERGED ARC WELDINGSUBMERGED ARC WELDING
POWERSOURCE
WORKPIECE
COMMONCONTACT
TUBE
b
L
0° - 90°
Weldingdirections
POWERSOURCE
WORKPIECE
SEPARATECONTACT TUBE
0° - 90°
Weldingdirections
POWERSOURCE
POWERSOURCE
Three electrodeThree electrode weldingwelding
Triple-wireTriple-wireelectrode weldingelectrode welding
EXPERIMENTAL SETUPEXPERIMENTAL SETUP
2
Weldingdirection
1
3
WIRE ARRANGEMENT
Contact tube
EM
Wirespools
Straighteningmechanism
Wire feedsystem
Contact tube
Workpiece
POWERSOURCE
1 2 3
EM
Wirespools
Straighteningmechanism
Wire feedsystem
Contact tube
Workpiece
POWERSOURCE
1 2 3
V
EM
Wirespools
Straighteningmechanism
Wire feedsystem
Contact tube
Workpiece
POWERSOURCE
1 2 3
V
mV
EM
Wirespools
Straighteningmechanism
Wire feedsystem
Contact tube
Workpiece
POWERSOURCE
1 2 3
V
mV
A/D CONVERTER
COMPUTER
Shunts
EXPERIMENTAL PROCEDUREEXPERIMENTAL PROCEDURE
EM
Wirespools
Straighteningmechanism
Wire feedsystem
Contact tube
Workpiece
POWERSOURCE
1 2 3
V
mV
A/D CONVERTER
COMPUTER
Shunts
Surfacing using SAW with:Surfacing using SAW with:•single-wire electrodesingle-wire electrode
• double-wire electrodedouble-wire electrode• triple-wire electrodetriple-wire electrode
&&Measurements ofMeasurements of
welding voltage and currentwelding voltage and current
RESULTS - oscillogramsRESULTS - oscillograms
Welding Welding parameters:parameters:I = 185 AI = 185 AU = 26 VU = 26 V
-400
-300
-200
-100
0
100
200
300
400
t [ms]
I [A
]
0
10
20
30
40
50
60
70
80
0 100 200 300 400 500 600 700
U [
V]
RESULTS - oscillogramsRESULTS - oscillograms
Welding Welding parameters:parameters:I = 2 x 185 AI = 2 x 185 AU = 26 VU = 26 V
-400
-300
-200
-100
0
100
200
300
400
t [ms]
I [A
]
0
10
20
30
40
50
60
70
80
0 100 200 300 400 500 600 700
U [
V]
RESULTS - oscillogramsRESULTS - oscillograms
Welding Welding parameters:parameters:I = 3 x 185 AI = 3 x 185 AU = 26 VU = 26 V
-400
-300
-200
-100
0
100
200
300
400
t [ms]
I [A
]
0
10
20
30
40
50
60
70
80
0 100 200 300 400 500 600 700
U [
V]
RESULTS - cyclogramsRESULTS - cyclograms
Single wireSingle wire
Double wireDouble wire
Triple wireTriple wire
0
5
10
15
20
25
30
35
0 50 100 150 200 250 300
I [A]
U [
V]
0
5
10
15
20
25
30
35
0 50 100 150 200 250 300
I1 [A]
U [
V]
0
5
10
15
20
25
30
35
0 50 100 150 200 250 300
I1 [A]
U [V
]
RESULTS - probability distributionRESULTS - probability distribution
Single wire Double wire Triple wireSingle wire Double wire Triple wire
0
2
4
6
8
10
12
50 100 150 200 250 300
I1, I2, I3 [A]
p [
%]
0
2
4
6
8
10
12
50 100 150 200 250 300
I1, I2 [A]
p [
%]
0
2
4
6
8
10
12
50 100 150 200 250 300
I [A]
p [
%]
0
2
4
6
8
10
12
50 100 150 200 250 300
I1, I2, I3 [A]
p [
%]
RESULTS - probability distributionRESULTS - probability distribution
Mean and standard deviationMean and standard deviation
VoltageU [V]
CurrentI1 [A]
CurrentI2 [A]
CurrentI3 [A]
mx 26.2 186 / /Single-wire x 1.19 26.15 / /mx 25.8 183 184 /Double-wire x 1.32 43.87 31.65 /mx 25.8 188 178 190Triple-wire x 1.07 37.55 32.99 28.63
RESULTS - Fourier’s analysisRESULTS - Fourier’s analysis
Single wireSingle wire
12 Hz
0 25 50 75 100 125 150
Hz
S (
)
12 Hz
0 25 50 75 100 125 150
Hz
S (
)
Voltage U Voltage U Current I Current I11
RESULTS - Fourier’s analysisRESULTS - Fourier’s analysis
Double wireDouble wire 7 Hz
0 25 50 75 100 125 150
Hz
S (
)
7 Hz
0 25 50 75 100 125 150
Hz
S (
)
7 Hz
0 25 50 75 100 125 150
Hz
S (
)
Voltage UVoltage U
Current ICurrent I1 1 Current ICurrent I22
22 Hz
10 Hz
2,5 Hz
0 25 50 75 100 125 150
Hz
S (
)
22 Hz
10 Hz2,5 Hz
0 25 50 75 100 125 150
Hz
S (
)
12 Hz
0 25 50 75 100 125 150
Hz
S (
)
10 Hz22 Hz
2,5 Hz
0 25 50 75 100 125 150
Hz
S (
)
Voltage UVoltage U Current ICurrent I11
Current ICurrent I22 Current ICurrent I33
RESULTS - Fourier’s analysisRESULTS - Fourier’s analysis
TripleTriplewirewire
RESULTS - correlationRESULTS - correlation
Single wireSingle wire
Double wireDouble wire
Triple wireTriple wire
VoltageU [V]
CurrentI1 [A]
CurrentI2 [A]
Voltage U [V] 1 / /Current I1 [A] -0.28 1 /Current I2 [A] 0.08 -0.64 1
VoltageU [V]
CurrentI1 [A]
CurrentI2 [A]
CurrentI3 [A]
Voltage U [V] 1 / / /Current I1 [A] -0.03 1 / /Current I2 [A] -0.35 -0.32 1 /Current I3 [A] -0.05 -0.34 -0.27 1
YX
YX
YX
,cov,
yixi mymxn
1YX ,cov
VoltageU [V]
CurrentI1 [A]
Voltage U [V] 1 /Current I1 [A] -0.19 1
CONCLUSIONSCONCLUSIONS
Single-wire electrode welding is more stableSingle-wire electrode welding is more stablethan double- or triple-wire electrode welding.than double- or triple-wire electrode welding.
Alternating material transfer occurs only Alternating material transfer occurs only in double-wire electrode welding.in double-wire electrode welding.
The arcs burning at each side (wires 1 and 3)The arcs burning at each side (wires 1 and 3)behave in a quite different manner than thebehave in a quite different manner than theone burning in the middle (wire 2).one burning in the middle (wire 2). 0
2
4
6
8
10
12
50 100 150 200 250 300
I1, I2, I3 [A]
p [
%]
-400
-300
-200
-100
0
100
200
300
400
t [ms]
I [A
]
0
10
20
30
40
50
60
70
80
0 100 200 300 400 500 600 700
U [
V]
0
5
10
15
20
25
30
35
0 50 100 150 200 250 300
I [A]
U [
V]
