Journal articles: 'Cold metal transfer welding'

1

Yang, Shuai, Yanfeng Xing, Fuyong Yang, and Juyong Cao. "Complex Behavior of Droplet Transfer and Spreading in Cold Metal Transfer." Shock and Vibration 2020 (November 17, 2020): 1–11. http://dx.doi.org/10.1155/2020/6650155.

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In intelligent manufacturing, an intelligent control method of welding process is an important process of intelligent welding manufacturing technology (IWMT). Metal transfer is a key factor to control the welding process. Metal transfer and droplet spreading are of vital importance for welding formation. A new theoretical model of cold metal transfer (CMT) in short-circuit transfer mode is proposed in this paper. In this model, the CMT welding process is regarded as a continuous process of arc heating, mass transfer, short-circuit, and spreading, and the relations between these processes are analyzed. The calculation equations used by the model can analyze the welding formation clearly and simplify the complex welding process into continuous physical behavior. The predicted welding width shows good agreement with the measurement results. The mechanism of increased welding width is also comprehensively analyzed. Results have a certain guiding effect on aluminum alloy welding process control.

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Venukumar, S., Muralimohan Cheepu, T. Vijaya Babu, and D. Venkateswarlu. "Cold Metal Transfer (CMT) Welding of Dissimilar Materials: An Overview." Materials Science Forum 969 (August 2019): 685–90. http://dx.doi.org/10.4028/www.scientific.net/msf.969.685.

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In recent years, the continuous growth in manufacturing industries such as light weight structures, demands in increasing of its performance and functionality enhance the use of different materials for producing hybrid structures and thus the requirements for joining of dissimilar joints. The physical and metallurgical properties of the materials are utilised to get combined properties to achieve the product performance. On the other hand the joining methods are continuously challenging for joining of dissimilar materials. The present study reviews and describes the effective welding method of cold metal transfer for joining of dissimilar materials and its state of the art research in various materials joining. Cold metal transfer joining mechanism, capabilities of joining of dissimilar metals and their performance are reviewed. The current and emerging techniques of cold metal transfer welding method are reviewed. Methods and other technological parameters selection are described and future challenges for improving research methods on joining of dissimilar metals using cold metal transfer. Keywords: Cold Metal Transfer, MIG welding, Dissimilar materials, Mechanical properties.

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S, Balamurugan, Ramamoorthi R, I. K. Kavin Jeysing, Kumar S, I. Mohammed Sharukhan, G. Muthu Prakash, and Madhan S. "Microstructure and Mechanical Properties of Cold Metal Transfer Welding AA6082-T4 Alloys." Indian Journal of Science and Technology 12, no. 42 (November 20, 2019): 1–8. http://dx.doi.org/10.17485/ijst/2019/v12i42/143273.

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Roată, Ionuţ Claudiu, Alexandru Pascu, Elena Manuela Stanciu, and Mihai Alin Pop. "Cold Metal Transfer Welding of Aluminum 5456 Thin Sheets." Advanced Materials Research 1029 (September 2014): 140–45. http://dx.doi.org/10.4028/www.scientific.net/amr.1029.140.

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This study aims to determine the optimal parameters for cold metal transfer MIG welding of aluminum thin sheets. Starting from this perspective, the filler material of Al5Mg full wire type and a synergic regime of welding with a low linear energy were used. The characterization of welded joints was achieved by macro – microscopic analyses, mechanical tests (microhardness and tensile) aiming to lower the thermo - mechanically affected zone. The results highlight the major influence of the welding parameters over the weld bead geometry and tensile behaviour of the joint.

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RIBEIRO, R. A., P. D. C. ASSUNÇÃO, E. B. F. DOS SANTOS, E. M. BRAGA, and A. P. GERLICH. "Globular-to-Spray Transition in Cold Wire Gas Metal Arc Welding." Welding Journal 100, no. 4 (April 1, 2021): 121–31. http://dx.doi.org/10.29391/2021.100.010.

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The electrical current required for a transition from globular to spray droplet transfer during gas metal arc welding (GMAW) is determined by the specified wire feed speed in the case of constant-voltage power supplies. Generally, in narrow groove welding, spray transfer is avoided, be-cause this transfer mode can severely erode the groove sidewalls. This work compared the globular-to-spray transition mechanism in cold wire gas metal arc welding (CW-GMAW) vs. standard GMAW. Synchronized high-speed imaging with current and voltage samplings were used to characterize the arc dynamics for different cold wire mass feed rates. Subsequently, the droplet frequency and diameter were estimated, and the parameters for a globular-to-spray transition were assessed. The results suggest that the transition to spray occurs in CW-GMAW at a lower current than in the standard GMAW process. The reason for this difference appears to be linked to an enhanced magnetic pinch force, which is mainly responsible for metal transfer in higher welding current conditions.

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Song, Hyun Soo, Bo Sung Choi, Jondo Yun, and Seung Tae Park. "Characterization of Cold Metal Transfer Welding Coated Steel." Journal of the Korean Society for Precision Engineering 32, no. 10 (October 1, 2015): 891–96. http://dx.doi.org/10.7736/kspe.2015.32.10.891.

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Talalaev, R., R. Veinthal, A. Laansoo, and M. Sarkans. "Cold metal transfer (CMT) welding of thin sheet metal products." Estonian Journal of Engineering 18, no. 3 (2012): 243. http://dx.doi.org/10.3176/eng.2012.3.09.

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Ribeiro, R. A., P. D. C. Assunção, and A. P. Gerlich. "Evaluation of Melting Efficiency in Cold Wire Gas Metal Arc Welding Using 1020 Steel as Substrate." Metals 14, no. 4 (April 21, 2024): 484. http://dx.doi.org/10.3390/met14040484.

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A key welding parameter to quantify in the welding process is the ratio of the heat required to melt the weld metal versus the total energy delivered to the weld, and this is referred to as the melting efficiency. It is generally expected that the productivity of the welding process is linked to this melting efficiency, with more productive processes typically having higher melting efficiency. A comparison is made between the melting efficiency in standard gas metal arc welding (GMAW) and cold wire gas metal arc welding (CW-GMAW) for the three primary transfer modes: short-circuit, globular, and spray regime. CW-GMAW specimens presented higher melting efficiency than GMAW for all transfer modes. Moreover, an increase in plate thickness in the spray transfer regime caused the melting efficiency to increase, contrary to what is expected.

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Mokrov, O., S. Warkentin, L. Westhofen, S. Jeske, J. Bender, R. Sharma, and U. Reisgen. "Simulation of wire metal transfer in the cold metal transfer (CMT) variant of gas metal arc welding using the smoothed particle hydrodynamics (SPH) approach." Materialwissenschaft und Werkstofftechnik 55, no. 1 (January 2024): 62–71. http://dx.doi.org/10.1002/mawe.202300166.

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AbstractCold metal transfer (CMT) is a variant of gas metal arc welding (GMAW) in which the molten metal of the wire is transferred to the weld pool mainly in the short‐circuit phase. A special feature here is that the wire is retracted during this strongly controlled welding process. This allows precise and spatter‐free formation of the weld seams with lower energy input. To simulate this process, a model based on the particle‐based smoothed particle hydrodynamics (SPH) method is developed. This method provides a native solution for the mass and heat transfer. A simplified surrogate model was implemented as an arc heat source for welding simulation. This welding simulation model based on smoothed particle hydrodynamics method was augmented with surface effects, the Joule heating of the wire, and the effect of the electromagnetic forces. The model of metal transfer in the cold metal transfer process shows good qualitative agreement with real experiments.

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Singh, Vivek, M. Chandrasekaran, Sutanu Samanta, and Kayaroganam Palanikumar. "Welding Investigation on GMAW−Cold Metal Transfer of AISI 201LN for Superior Weld Quality." International Journal of Manufacturing, Materials, and Mechanical Engineering 10, no. 4 (October 2020): 1–12. http://dx.doi.org/10.4018/ijmmme.2020100101.

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Austenitic stainless steel of AISI 201LN grade has found applications in liquefied natural gas tanks and cryogenic components. They are fabricated using gas tungsten arc welding (GTAW), but weld speed is low due to manual operation. This work aims welding investigation on AISI 201LN Gr. steel with a new hybrid welding approach (i.e., gas metal arc welding [GMAW] combined cold metal transfer [CMT]) for obtaining superior weld quality. Weld experiments were carried out at different welding speed, for example, 300, 400, 600, and 900 mm/min, to study weld quality and its mechanical properties. The microstructural examination of test coupons at higher welding speed shows finer structure in heat-affected zone as well as on weld metal. It was observed that the weld coupon having low heat input (at high weld speed) has maximum tensile strength. Scanning electron microscope analysis shows finer dimples at higher welding speed confirming ductile mode of fracture.

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Zhang, An, Yanfeng Xing, Xiaobing Zhang, Fuyong Yang, and Juyong Cao. "Analysis of Controlled Driving and Spreading Behavior of Molten Pool in Cold Metal Transfer." Energies 15, no. 4 (February 21, 2022): 1575. http://dx.doi.org/10.3390/en15041575.

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The controlled short-circuit transfer is used to control the heat input of the molten pool and the base metal in the cold metal transfer welding process, including droplet formation, droplet transfer and molten pool flow. Based on the influence of arc pressure on the surface of the molten pool, droplet impact and residual energy on the flow behavior of the molten pool, this research proposes the arc pressure driving model, the droplet impact driving model and the residual energy transfer model on the molten pool surface respectively, and on this basis, a theoretical model of controlled driving and spreading of the cold metal transition bath is proposed. The theoretical relationship between the surface shape of the keyhole and the driving force, and the relationship between the surface shape of the molten pool and the welding current are established. The model accurately predicts the formation width and contact angle of the molten pool in a specific interval, which can better control the welding process and geometry.

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İrizalp, Alaattin Ozan, Hülya Durmuş, Nilay Yüksel, and İlyas Türkmen. "Cold metal transfer welding of AA1050 aluminum thin sheets." Matéria (Rio de Janeiro) 21, no. 3 (September 2016): 615–22. http://dx.doi.org/10.1590/s1517-707620160003.0059.

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13

Burhanuddin, N. M., N. Redzuan, N. Ahmad, I. Sudin, and M. F. A. Zaharuddin. "Brief Review on Dissimilar Welding Using Cold Metal Transfer." IOP Conference Series: Materials Science and Engineering 884 (July 21, 2020): 012115. http://dx.doi.org/10.1088/1757-899x/884/1/012115.

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14

Ragrin, N. A., and Zh Sh Belekova. "RESEARCH AND DEVELOPMENT OF CMT WELDING MODE (COLD METAL TRANSFER) OF FINE GRAIN LIGHT ALLOYS." Vestnik of the Kyrgyz-Russian Slavic University 22, no. 8 (2022): 135–39. http://dx.doi.org/10.36979/1694-500x-2022-22-8-135-139.

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15

Verbiţchi, Victor, Radu Cojocaru, Lia Nicoleta Boţilă, and Cristian Ciucă. "Examination of Noxious Emissions of the Welding Process “Cold Metal Transfer (CMT)”." Advanced Materials Research 1138 (July 2016): 25–30. http://dx.doi.org/10.4028/www.scientific.net/amr.1138.25.

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For the examination of noxious emissions, cladding tests were performed according to EN ISO 6847. The filler materials were 1.2 mm diameter wire-electrodes, made of tin bronze, aluminium bronze, austenitic stainless steel, duplex stainless steel and nickel alloy.The low-energy metal transfer welding process, named CMT (cold metal transfer) was examined, on the welding source type Trans Puls Synergic 2700 CMT, of 270 A, produced by the company Fronius, Austria. For sampling welding smoke particles, an Apex type pump was used. For measuring the concentration of gases emitted by welding, a Triple Plus type multi-gas detector was applied.The particulate emission rate is 0.500 mg / m3 in the breathing zone, according to ISO 10882-1. For comparison, the measured emission rate is from 0.877 to 2.513 mg / m3 in the welding zone, according to ISO 15011-1. The concentration of the emitted gases is in the ranges: 0.14 to 0.16% CO2; 0.1-0.2 ppm NO2; 0-15 ppm H2; 0-5 ppm CO. These concentration levels are below the exposure limits (8 hours per day, five days a week): 5% CO2; 1.0 ppm NO2; 30 ppm CO. In conclusion, the emissions from the CMT welding process are without health risk for the welder.

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Li, Gang, Shengyu Xu, Xiaofeng Lu, Xiaolei Zhu, Yupeng Guo, and Jufeng Song. "Effect of welding speed on microstructure and mechanical properties of titanium alloy/stainless steel lap joints during cold metal transfer method." Metallurgical Research & Technology 117, no. 5 (2020): 506. http://dx.doi.org/10.1051/metal/2020052.

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Cold metal transfer (CMT) technique is developed for lap joining of titanium (Ti) alloy to stainless steel (SS) with CuSi3 filler wire. The effect of welding speed on the microstructure and mechanical properties of Ti/SS lap joints is investigated. The results indicate that the wetting angle of the lap joints gradually increases and the weld width decreases with increasing the welding speed. It is found that many coarse phases in the fusion zone are rich in Ti, Fe and Si etc, inferring as Fe–Si–Ti ternary phase and/or Fe2Ti phase at low welding speed. Many fine spherical particles in the fusion zone are considered as iron-rich particles at high welding speed. The transition layer are exhibited at the Ti–Cu interface. With increasing the heat input, the intermetallic layer becomes thicker. A variety of brittle intermetallic compounds (IMCs) are identified in the lap joints. The shear strength of the joints increases with increasing the welding speed. Two fracture modes occur in the lap joints at low welding speed. Thicker reaction layer causes brittle fracture and poor joint strength. The Fe–Ti–Si and Fe2Ti phase within the fusion zone are detrimental to the joint strength. The fracture surface of the joints is dominated by smooth surface and tear pattern at high welding speed. The fracture mode of the joints is merely along the Ti–Cu interface.

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Fydrych, D., J. Łabanowski, J. Tomków, and G. Rogalski. "Cold Cracking Of Underwater Wet Welded S355G10+N High Strength Steel." Advances in Materials Science 15, no. 3 (September 1, 2015): 48–56. http://dx.doi.org/10.1515/adms-2015-0015.

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Abstract Water as the welding environment determines some essential problems influencing steel weldability. Underwater welding of high strength steel joints causes increase susceptibility to cold cracking, which is an effect of much faster heat transfer from the weld area and presence of diffusible hydrogen causing increased metal fragility. The paper evaluates the susceptibility to cold cracking of the high strength S355G10+N steel used, among others, for ocean engineering and hydrotechnical structures, which require underwater welding. It has been found from the CTS test results that the investigated steel is susceptible to cold cracking in the wet welding process.

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Zhang, Chao, Mingfang Wu, Yuxin Wang, and Juan Pu. "Microstructure and mechanical properties of cold metal transfer welded galvanized steel/magnesium alloy dissimilar joints." International Journal of Modern Physics B 34, no. 01n03 (December 16, 2019): 2040060. http://dx.doi.org/10.1142/s0217979220400603.

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The joining of magnesium alloy to galvanized steel was realized by cold metal transfer method with AZ31 magnesium alloy welding wire. Weld appearance, microstructure and tensile properties of Mg–steel joints under various welding parameters were investigated with different welding heat inputs. The results showed that magnesium alloy-steel brazed joints had good weld appearance. When the welding heat input was 141 J/mm, Zn elements were enriched in the Zn-rich zone (ZRZ), and the interface layer was composed of a large portion of Mg–Zn phases and minor Mg–Al phases. With the increase of welding heat input, Zn elements in the ZRZ gradually decreased, Fe/Al phase appeared in the interface layer, and the strength of welding joint increased. When the welding heat input was 159 J/mm, the tensile strength of welding joint reached the maximum value of 198 MPa. However, when the welding input was increased to 181 J/mm, Zn element in the ZRZ was burnt and volatilized seriously, resulting in poor wetting and spreading properties of liquid phase at the interface zone of the steel.

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Brezinová, Janette, Miroslav Džupon, Marek Vojtko, Ján Viňáš, Ondrej Milkovič, Jakub Brezina, Anna Guzanová, and Dagmar Draganovská. "Application of Cold Metal Transfer Welding for High Pressure Die Casting Mold Restoration." Metals 9, no. 11 (November 18, 2019): 1232. http://dx.doi.org/10.3390/met9111232.

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This paper presents results of the research focused on the possibility of the restoration of the shape parts of molds made of X15CrNiSi20-12 (EN 100 95) heat-resistant austenitic chromium-nickel stainless steel working in high-pressure die casting of aluminum alloys by clad welding. There were tested two welding wires—E Ni 6625 and E 18 8 Mn B 2 2—deposited on X15CrNiSi20-12 (EN 100 95) tool steel using cold metal transfer (CMT) welding in a protective atmosphere of Ar. The resistance of welds was tested against dissolution in molten aluminum alloy ENAC-AlSi9 and the testing procedure was designed. The resistance of welds against dissolution were assessed by exposition of welded clads in an aluminum melt for 120 and 300 min. The EDX semi-quantitative microanalyses of element distribution were performed at the welding–melt interface, and build-ups were also observed on the surface of welded clads.

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Cao, R., M. Jing, Z. Feng, and J. H. Chen. "Cold metal transfer welding–brazing of magnesium to pure copper." Science and Technology of Welding and Joining 19, no. 6 (April 8, 2014): 451–60. http://dx.doi.org/10.1179/1362171814y.0000000204.

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Azar, Amin S. "A heat source model for cold metal transfer (CMT) welding." Journal of Thermal Analysis and Calorimetry 122, no. 2 (June 23, 2015): 741–46. http://dx.doi.org/10.1007/s10973-015-4809-4.

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Prabandono, Bayu, Agnes Putri Kartika Santosa, Devinta Putri Ardani, Agus Kurniawan, and Mirza Yusuf. "Analisis Pengujian Tarik dan Sebaran unsur pada Pengelasan Aluminium – Mild Steel menggunakan Metode Cold Metal." Quantum Teknika : Jurnal Teknik Mesin Terapan 4, no. 1 (December 19, 2022): 1–6. http://dx.doi.org/10.18196/jqt.v4i1.16092.

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The technology that has been developed in recent years is the production of fusion welded plates between two different materials, for example, steel with other materials such as aluminum. Combining the two materials, aluminum and mild steel, will undoubtedly produce a material connection with good properties, for example, in a vehicle car frame. However, these two materials have different melting points, mild steel has a high melting point, and aluminum has a low melting point in the inner layer. This research aims to determine the welding results and the microstructure between aluminum plates and mild steel. The Cold Metal Transfer (CMT) welding process provides a potential method for joining dissimilar metals. In this study, various 4 mm thick aluminum alloys (Al 1100) were joined to 4 mm thick mild steel (SPHC) by CMT welding technology. It was concluded that combining aluminum alloys with mild steel using the cold metal transfer method was feasible. The optimum process variable for welding aluminum-mild steel dimensions 250 mm × 100 mm × 4 mm can be obtained with ER70S-6 wire, ArCO2 shielding gas, wire feed speed 13 m/min, and welding speed e8 mm/s.The tensile strength of the joint first increases and then decreases as the welding current increases, the highest tensile strength can reach 73.35 MPa.

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Han, Xiaohui, Zhibin Yang, Yin Ma, Chunyuan Shi, and Zhibin Xin. "Comparative Study of Laser-Arc Hybrid Welding for AA6082-T6 Aluminum Alloy with Two Different Arc Modes." Metals 10, no. 3 (March 22, 2020): 407. http://dx.doi.org/10.3390/met10030407.

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The effects of arc modes on laser-arc hybrid welding for AA6082-T6 aluminum alloy were comparatively studied. Two arc modes were employed: pulsed metal inert gas arc and cold metal transfer arc. The results indicated that joints without porosity, undercutting, or other defects were obtained with both laser-pulsed metal inert gas hybrid welding (LPMHW) and laser-cold metal transfer hybrid welding (LCHW). Spatter was reduced, and even disappeared, during the LCHW process. The sizes of equiaxed dendrites and the width of the partially melted zone in the LPMHW joint were larger than those in the LCHW joint. The microhardness in each zone of the LPMHW joint was lower than that of the LCHW joint. The softening region in the heat-affected zone of the LPMHW joint was wider than that of the LCHW joint. The tensile strength of the LCHW joint was higher than that of the LPMHW joint. For the two joints, the fractures all occurred in the softening region in the heat-affected zone, and the fracture morphologies showed ductile fracture features. The dimples in the fractograph of the LCHW joint were deeper than those of the LPMHW joint.

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Bolotov, Sergey, Aleksandr Homchenko, Aleksandr Shul'ga, and Evgeniya Bolotova. "INFORMATION-MEASURING COMPLEX FOR INVESTIGATION OF MELTING AND ELECTRODE METAL TRANSFER AT ARC WELDING." Bulletin of Bryansk state technical university 2020, no. 6 (May 30, 2020): 4–11. http://dx.doi.org/10.30987/1999-8775-2020-6-4-11.

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The purpose of the paper consists in the description of the procedure for investigations and software-hardware means for arc welding with a melting electrode in protective gas environment with the controlled transfer of electrode metal and its visualization. For investigations of quick electrode metal transfer processes there was used Evercam 1000-4-C digital video-camera and RKDP-0401recorder of welding mode parameters. For video-control of the process there was used a method of active illumination with the further image filtration. It is determined that the visualization of a welding drop transfer dynamics during arc welding with melting electrode in protective gases should be carried out in the infrared range on one side limited with the curve of a spectral transmission of light filters – 950 nm, and on the other side of a matrix sensitivity spectral curve of a rapid camera -1050 nm. There is developed software in the environment of the LabVIEW graphical programming allowing the fulfillment of adjustment and programming welding mode parameters and high-speed shooting, device synchronization, superposition on oscillograms of electric parameters of the electrode metal image transfer, definition of power characteristics at different interval of drop transfer. The CMT (Cold Metal Transfer) process with the aid of the equipment of Fronius TransPuls Synergic 3200 is investigated. It is defined that for arc welding in protective gases an optimum frequency of video-shooting is 1500-2000 shots per second at resolution from 640x608 pixels to 320x400 pixels that allows analyzing efficiently rapid processes of drop transfer.

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Frátrik, Martin, and Miloš Mičian. "Using the cold metal transfer (CMT) method for wire arc additive manufacturing (WAAM) applications." Technológ 15, no. 1 (2023): 76–79. http://dx.doi.org/10.26552/tech.c.2023.1.14.

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This work deals with the possibilities of applying the MAG-CMT welding method for the purpose of wire arc additive manufacturing (WAAM). The WAAM method was operated using an industrial robot and welding device for MAG welding. The aim of the work was to compare three methods of laying layers in order to assess their mutual mixing. Cross-shaped perpendicular walls that were mutually connected as of the welded component were assessed. The geometry, macrostructure, and total operating costs of individual variants were evaluated. The result was the determination of the most accurate and most economical variant of laying layers.

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Wang, Wen Quan, Qing Liang Meng, and Li Yuan Niu. "Study on CMT Welding of Stainless Steel Railway Vehicle Body." Advanced Materials Research 936 (June 2014): 1769–74. http://dx.doi.org/10.4028/www.scientific.net/amr.936.1769.

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Abstract. Cold metal transfer (CMT) process is a modified inert gas metal welding process,which characterizes of low heat input and no spatter welding comparing with traditional GMAW process.In this paper,research of the CMT welding features of stainless steel sheet has been conducted.The effects of welding parameters including wire feed rate,welding speed and arc-length modification coefficient on mechanical properties and surface morphology were investigated.In addition,optical micrograph(OM) and scanning electron microscope(SEM) were used to analyze the weld microstructure,and microstructural characteristics were discussed as well.In the end,the optimum welding parameters which were used in real production and achieved good effect were obtained by means of orthogonal experiment.

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Pramod, R., N. Siva Shanmugam, and CK Krishnadasan. "Studies on cold metal transfer welding of aluminium alloy 6061-T6 using ER 4043." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 234, no. 7 (April 14, 2020): 924–37. http://dx.doi.org/10.1177/1464420720917175.

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Aluminium alloy 6061-T6 is utilized in aerospace industry for developing pressure vessel liner. Cold metal transfer is a promising welding process used in fabricating aluminium structures. The present work is focussed to achieve an optimum welding parameter for joining a 3.5-mm thick pressure vessel and to examine the mechanical properties and metallurgical nature of the weldment. The welded joint was evaluated as defect free using radiography test. The joint efficiency (66.61%) and measured microhardness of weldment (59.78 HV) exhibited promising results. The effect of grain coarsening in the heat affected zone (HAZ) and weld zone is attributed to the thermal gradients during welding. Dissipation of small amounts of strengthening elements Si and Mg during welding leads to reduction in mechanical properties. X-ray diffraction peaks revealed the presence of intermetallic Al–Si and Fe–Si in the weld zone. Fractography examination confirms the ductile type of failure in the fractured surface of the tensile samples.

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Silvayeh, Zahra, Bruno Götzinger, Werner Karner, Matthias Hartmann, and Christof Sommitsch. "Calculation of the Intermetallic Layer Thickness in Cold Metal Transfer Welding of Aluminum to Steel." Materials 12, no. 1 (December 22, 2018): 35. http://dx.doi.org/10.3390/ma12010035.

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The intermetallic layer, which forms at the bonding interface in dissimilar welding of aluminum alloys to steel, is the most important characteristic feature influencing the mechanical properties of the joint. In this work, horizontal butt-welding of thin sheets of aluminum alloy EN AW-6014 T4 and galvanized mild steel DC04 was investigated. In order to predict the thickness of the intermetallic layer based on the main welding process parameters, a numerical model was created using the software package Visual-Environment. This model was validated with cold metal transfer (CMT) welding experiments. Based on the calculated temperature field inside the joint, the evolution of the intermetallic layer was numerically estimated using the software Matlab. The results of these calculations were confirmed by metallographic investigations using an optical microscope, which revealed spatial thickness variations of the intermetallic layer along the bonding interface.

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Elrefaey, A. "Effectiveness of cold metal transfer process for welding 7075 aluminium alloys." Science and Technology of Welding and Joining 20, no. 4 (March 19, 2015): 280–85. http://dx.doi.org/10.1179/1362171815y.0000000017.

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Cao, R., Z. Feng, Q. Lin, and J. H. Chen. "Study on cold metal transfer welding–brazing of titanium to copper." Materials & Design (1980-2015) 56 (April 2014): 165–73. http://dx.doi.org/10.1016/j.matdes.2013.10.044.

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Zapico, Eriel Pérez, Adrian H. A. Lutey, Alessandro Ascari, Carlos R. Gómez Pérez, Erica Liverani, and Alessandro Fortunato. "An improved model for cold metal transfer welding of aluminium alloys." Journal of Thermal Analysis and Calorimetry 131, no. 3 (November 7, 2017): 3003–9. http://dx.doi.org/10.1007/s10973-017-6800-8.

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Pickin, C. G., and K. Young. "Evaluation of cold metal transfer (CMT) process for welding aluminium alloy." Science and Technology of Welding and Joining 11, no. 5 (September 2006): 583–85. http://dx.doi.org/10.1179/174329306x120886.

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Lei, HaiYang, YongBing Li, and Blair E. Carlson. "Cold metal transfer spot welding of 1 mm thick AA6061-T6." Journal of Manufacturing Processes 28 (August 2017): 209–19. http://dx.doi.org/10.1016/j.jmapro.2017.06.004.

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Shanker, Hari, and Reeta Wattal. "A comprehensive survey on the cold metal transfer process for additive manufacturing." Journal of Physics: Conference Series 2570, no. 1 (August 1, 2023): 012001. http://dx.doi.org/10.1088/1742-6596/2570/1/012001.

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Abstract Cold metal transfer (CMT) welding has shown significant interest in the research community because of its excellent capabilities. A low heat input associated with the CMT process has made this technology important for difficult-to-weld stuff like aluminum and its alloys and dissimilar material joining. Nowadays, the primary emphasis has been on avoiding the negative impact of joining in order to achieve a longer service life. The aim of this analysis is to recognize the process parameters that affect additive manufacturing in terms of material and process by using CMT and its variants. It is observed that CMT as an advanced welding approach has gained a significant attraction of researchers in investigating it for additive manufacturing which leads to the advancement of a renowned wire and arc additive manufacturing, abbreviately called (WAAM) process. Bead width, height, current, and voltage are the main parameters that are influenced by linear energy density and in turn, leads to the quality of the fabricated products.

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Wang, Yang, Zhongyin Zhu, Guoqing Gou, Lin Peng, Yali Liu, Tao Yang, and Wei Gao. "Arc characteristics and metal transfer behavior of CMT+P process for Q235 steel of titanium-steel composite plate." International Journal of Modern Physics B 33, no. 01n03 (January 30, 2019): 1940040. http://dx.doi.org/10.1142/s021797921940040x.

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The cold metal transfer (CMT) with addition of pulses (CMT[Formula: see text]P) process is a new CMT welding method. This paper uses a high-speed camera and electrical signal synchronization acquisition system to perform a CMT[Formula: see text]P welding test on a 10 mm thick Q235 steel plate, and performs arc characteristic and droplet transfer behavior in the welding process. It has been founded that under relatively small currents and voltages, the CMT[Formula: see text]P transfer mode is a combination of a projected transfer mode with one droplet in the pulse period and a short circuit transfer mode during the CMT period. The process is stable with little spatter; at relatively large currents and voltages, the transition mode is the combination of pulse transfer, spray transfer and short circuit transfer. It results in one or more droplets that enter the pool both in pulse transfer in the spray transfer mode during the pulse period and in the short circuit transfer mode during the CMT period in a weld cycle.

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Naik, Bishal, and Mahendrakumar Madhavan. "Structural behaviour of Cold‐Formed Steel back‐to‐back welded sections subjected to longitudinal shear." ce/papers 6, no. 3-4 (September 2023): 2014–19. http://dx.doi.org/10.1002/cepa.2761.

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AbstractThe current study focuses on understanding the behaviour of flare v‐groove welds on back‐to‐back connected Cold‐Formed Steel welded sections (G300) subjected to longitudinal shear. A novel welding technique called Cold Metal Transfer (CMT) welding was used for fabrication with copper‐coated steel welding wire as a filler metal (ER70S‐6). This mode of welding has the advantage of controlled material deposition compared to the spray or globular mode of welding. Lap shear tests were carried out on unlipped channels including thickness of the weld, and length of the weld. The weld geometry was observed under an optical microscope after polishing and chemical etching of the weld cross‐section, as American Iron and Steel Institute (AISI) design standard provides no specification on thickness of flare v‐groove welds for CMT welding process. In general, the lap shear specimens failed in plate tearing failure mode and brittle fracture of weld at the weld contours. Additionally, the appropriateness of AISI's shear design strength equations for flare v‐groove welds was verified and preliminary design guidelines are provided addressing the lacunae in AISI design standard.

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Girinath, B., N. Siva Shanmugam, and K. Sankaranarayanasamy. "Weld bead graphical prediction of cold metal transfer weldment using ANFIS and MRA model on Matlab platform." SIMULATION 95, no. 8 (November 15, 2018): 725–36. http://dx.doi.org/10.1177/0037549718809162.

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A difficult task for the transport sector is to make its assemblies lighter and perform more efficiently. Use of aluminum and its alloys has increased extensively in this sector because of reduction in weight of the vehicles and resulting energy savings. High thermal conductivity and thermal expansion pose difficulty in welding of these alloys. Cold metal transfer (CMT), a low heat input welding process, is the best choice for welding of these alloys. However, controlling the welding input parameters is highly necessary to obtain defect-free and high strength welded joints. In the present study, an attempt is made to develop a Matlab software-based application by two approaches, such as multiple regression analysis (MRA) and adaptive neuro-fuzzy inference system (ANFIS), for predicting the complete weld bead shape (graphical representation) of AA5052 using the CMT welding process. The data inputs used for both approaches are welding current (A) and welding speed (mm/min), respectively. A graphical interface is built to help the user to choose welding input parameters and obtain directly a representation of the weld bead profile in graphical form. In addition, the output response shows the complete weld bead shape, which is defined by the X and Y coordinates of the various points in the weld bead profile. The results are validated with randomized tests against the weld bead shape predicted by Matlab. Comparatively, ANFIS is the more effective method for predicting the weld bead profile and shows better agreement with the experimental profile than MRA. Further, the reliability and stability of the ANFIS model were determined from the mean absolute error percentage, root mean square error values, and linear R2fit model, confirming that the ANFIS-based prediction is in better agreement with the experimental values than MRA.

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Muncut, Elena, Ion Aurel Perianu, Dan Glavan, and Gheorghe Sima. "Structural Analysis for Joining Dissimilar Thin Sheets with CMT (Cold Metal Transfer) Process." Advanced Materials Research 1111 (July 2015): 49–55. http://dx.doi.org/10.4028/www.scientific.net/amr.1111.49.

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The work includes work steps for joining thin sheets with a thickness ranging from1.0 mm (according to EN10327-2004). The study presents the following steps: problems arising from joining with CMT weld-brazing process of galvanized low-carbon steel sheets, used as filler material CuSi3. This is due to the fact that copper induces: grain refinement by lowering the transformation temperature and precipitation hardening after rapid cooling and tempering the theoretical and experimental study of these problems leads to the possibility of combining copper with iron. This is an experiment to investigate the formation of interlayer containing intermetallic compounds, inter layer located between the molten material and the base material. An important part of the study was the optimizing of weld-brazing parameters: welding current, welding speed and dynamic correction factor Ina.Keywords: galvanized sheets steel, joining, weld-brazing CMT, preserving the zinc layer, intermetallic layer.

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Chen, Chen, Chenhao Gao, and Yanfeng Xing. "Investigations on the Dissimilar Metal Joints Capability between Aluminum Alloy and Steel under CMT Welding." MATEC Web of Conferences 228 (2018): 04007. http://dx.doi.org/10.1051/matecconf/201822804007.

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Sustainable lightweight vehicle design has becoming a key trend in the future. A new way to join aluminum alloys and steel sheet. Cold metal transfer (CMT) welding of thin sheet metal products. Determination of equilibrium wire-feed-speeds welding-speeds and arc length. Seam formation and microstructure of CMT were researched. Not only that, but optimum welding parameters were analyzed. Study of welding joint microstructure of compound layer on welding joint. Comparing the steel side of welding seam. The aluminum alloy siding grain size was larger. After tensile test, joint was fractured on the aluminum alloy side. Warp deformation occurred on aluminum side. Displacement of warp deformation became larger along with the increase of welding current. The results reviewed in this article indicate that the aluminum alloy fractured is more preferable to steel. CMT welding has found applications in automobile industries, defence sectors and power plants as a method of additive manufacturing.

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Panchenko, Oleg, Dmitry Kurushkin, Fedor Isupov, Anton Naumov, Ivan Kladov, and Margarita Surenkova. "Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V." Materials 14, no. 9 (May 10, 2021): 2457. http://dx.doi.org/10.3390/ma14092457.

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In wire arc additive manufacturing of Ti-alloy parts (Ti-WAAM) gas metal arc welding (GMAW) can be applied for complex parts printing. However, due to the specific properties of Ti, GMAW of Ti-alloys is complicated. In this work, three different types of metal transfer modes during Ti-WAAM were investigated: Cold Metal Transfer, controlled short circuiting metal transfer, and self-regulated metal transfer at a direct current with a negative electrode. Metal transfer modes were studied using captured waveform and high-speed video analysis. Using these modes, three walls were manufactured; the geometry preservation stability was estimated and compared using effective wall width calculation, the microstructure was analyzed using optical microscopy. Transfer process data showed that arc wandering depends not only on cathode spot instabilities, but also on anode processing properties. Microstructure analysis showed that each produced wall consists of phases and structures inherent for Ti-WAAM. α-basketweave in the center of and α-colony on the grain boundary of epitaxially grown β-grains were found with heat affected zone bands along the height of the walls, so that the microstructure did not depend on metal transfer dramatically. However, the geometry preservation stability was higher in the wall, produced with controlled short circuiting metal transfer.

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Klobčar, Damjan, Maja Lindič, and Matija Bušić. "Wire arc additive manufacturing of mild steel." Materials and Geoenvironment 65, no. 4 (December 1, 2018): 179–86. http://dx.doi.org/10.2478/rmzmag-2018-0015.

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AbstractThis paper presents an overview of additive manufacturing technologies for production of metal parts. A special attention is set to wire arc additive manufacturing (WAAM) technologies, which include MIG/MAG welding, TIG welding and plasma welding. Their advantages compared to laser or electron beam technologies are lower investment and operational costs. However, these processes have lower dimensional accuracy of produced structures. Owing to special features and higher productivity, the WAAM technologies are more suitable for production of bigger parts. WAAM technology has been used together with welding robot and a cold metal transfer (CMT) power source. Thin walls have been produced using G3Si1 welding wire. The microstructure and hardness of produced structures were analysed and measured. A research was done to determine the optimal welding parameters for production of thin walls with smooth surface. A SprutCAM software was used to make a code for 3D printing of sample part.

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Yang, Shanglu, Jing Zhang, Jin Lian, and Yongpin Lei. "Welding of aluminum alloy to zinc coated steel by cold metal transfer." Materials & Design 49 (August 2013): 602–12. http://dx.doi.org/10.1016/j.matdes.2013.01.045.

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Madhavan, S., M. Kamaraj, and L. Vijayaraghavan. "Cold metal transfer welding of aluminium to magnesium: microstructure and mechanical properties." Science and Technology of Welding and Joining 21, no. 4 (April 19, 2016): 310–16. http://dx.doi.org/10.1080/13621718.2015.1108070.

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Rajeev, G. P., M. Kamaraj, and Srinivasa R. Bakshi. "Effect of correction parameters on deposition characteristics in cold metal transfer welding." Materials and Manufacturing Processes 34, no. 11 (June 14, 2019): 1205–16. http://dx.doi.org/10.1080/10426914.2019.1628260.

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Agudo, L., S. Weber, Haroldo Pinto, Enno Arenholz, Juergen Wagner, Heinz Hackl, Jürgen Bruckner, and Anke Pyzalla. "Study of Microstructure and Residual Stresses in Dissimilar Al/Steels Welds Produced by Cold Metal Transfer." Materials Science Forum 571-572 (March 2008): 347–53. http://dx.doi.org/10.4028/www.scientific.net/msf.571-572.347.

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Recently a new welding technique, the so-called ‘Cold Metal Transfer’ (CMT) technique was introduced, which due to integrated wire feeding leads to lower heat input and higher productivity compared to other gas metal arc (GMA) techniques. Here microstructure formation and residual stress state in dissimilar steel to aluminum CMT welds are investigated. The intermetallic phase seam between the filler and the steel is only a few micrometers thick. Residual stress analyses reveal the formation of the typical residual stress state of a weld without phase transformation. Both in longitudinal and in transversal direction compressive residual stresses exist in the steel plate parent material, tensile residual stresses are present in the heat affected zone of the steel and the aluminum alloy. The area containing tensile residual stresses is larger in the aluminum alloy due to its higher heat conductivity than in the steel. Due to the symmetry in the patented voestalpine welding geometry and the welding from bottom and face side of the weld, the residual stress distributions at the top and at the bottom side of the weld are very similar.

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Lee, Huijun, Changwook Ji, and Jiyoung Yu. "Effects of welding current and torch position parameters on bead geometry in cold metal transfer welding." Journal of Mechanical Science and Technology 32, no. 9 (September 2018): 4335–43. http://dx.doi.org/10.1007/s12206-018-0831-3.

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Aberbache, Hichem, Alexandre Mathieu, Nathan Haglon, Rodolphe Bolot, Laurent Bleurvacq, Axel Corolleur, and Fabrice Laurent. "Numerical Study of the Cold Metal Transfer (CMT) Welding of Thin Austenitic Steel Plates with an Equivalent Heat Source Approach." Journal of Manufacturing and Materials Processing 8, no. 1 (January 26, 2024): 20. http://dx.doi.org/10.3390/jmmp8010020.

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The CMT (cold metal transfer) arc welding process is a valuable joining method for assembling thin sheets, minimizing heat transfers, and reducing subsequent deformations. The study aims to simulate the CMT welding of thin stainless-steel sheets to predict temperature fields and deformations. Both instrumented tests and numerical simulations were conducted for butt-welding of sheets with a thickness of 1 to 1.2 mm. Weld seam samples were observed to identify equivalent heat sources for each configuration. The electric current and voltage were monitored. Temperature measurements were performed using K-type thermocouples, as well as displacement measurements via the DIC (digital image correlation) technique. Thermomechanical simulations, considering phase changes and the actual seam geometry induced by filler material, were conducted using an equivalent heat source approach. A unique heat exchange coefficient accounting for thermal losses was identified. By incorporating these losses into thermal calculations, a good agreement was found between measured and calculated temperatures. Mechanical calculations allowed for the recovery of the horse saddle form after actual welding, with a relative difference of less than 10% in angular distortion between calculated and measured values.

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Li, Zhuoxin, Lingshan Ou, Yipeng Wang, Hong Li, Mariusz Bober, Jacek Senkara, and Yu Zhang. "Solidification Cracking Restraining Mechanism of Al-Cu-Mg-Zn Alloy Welds Using Cold Metal Transfer Technique." Materials 16, no. 2 (January 11, 2023): 721. http://dx.doi.org/10.3390/ma16020721.

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Aluminum alloy 7075 (with 7055 and 7150 filler wires) was welded using a digital welding machine that can switch arc mode between MIG, CMT and CMT+P modes. The transverse-motion weldability test of joints welded under different arc modes showed that the solidification cracking susceptibility was lower in CMT-technique-based welds than in MIG welds. The temperature cycle of the welding pool under different arc modes was recorded using mini-thermocouples, which showed that the cooling rate was lower in CMT welded samples than in MIG welded samples. The low cooling rate promoted the growth of α-Al dendrites through the back diffusion effect. Electron probe micro-analysis showed that micro-segregation of the α-Al dendrites was lower in the CMT welded samples than in the MIG welded samples. The T-(fAl)1/2 curve of each weld was calculated, which showed that CMT-based welding enhanced the bridging of adjacent α-Al dendrites, reducing the tendency for solidification cracking.

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Naik, Bishal, and Mahendrakumar Madhavan. "Structural performance of cold metal transfer welding technique on cold-formed steel flare v-groove welds." Thin-Walled Structures 190 (September 2023): 110963. http://dx.doi.org/10.1016/j.tws.2023.110963.

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Qin, Youqiong, Xi He, and Wenxiang Jiang. "Influence of Preheating Temperature on Cold Metal Transfer (CMT) Welding–Brazing of Aluminium Alloy/Galvanized Steel." Applied Sciences 8, no. 9 (September 14, 2018): 1659. http://dx.doi.org/10.3390/app8091659.

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Bead-on-plate cold metal transfer (CMT) brazing and overlap CMT welding–brazing of 7075 aluminium alloy and galvanized steel at different preheating temperatures were studied. The results indicated that AlSi5 filler wire had good wettability to galvanized steel. The preheating treatment can promote the spreadability of liquid AlSi5. For the overlap CMT welding–brazed joint, the microstructure of the joint was divided into four zones, namely, the interfacial layer, weld metal zone, zinc-rich zone, and heat affected zone (HAZ). The load force of the joints without preheating and 100 °C preheating temperature was 8580 N and 9730 N, respectively. Both of the joints were fractured in the fusion line with a ductile fracture. Further increasing the preheating temperature to 200 °C would decrease the load force of the joint, which fractured in the interfacial layer with a brittle fracture.

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Journal articles on the topic 'Cold metal transfer welding'

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