Multiple output analysis for advanced waveform and controlled short-circuit MIG/MAG variants

The latest advancements of MIG/MAG welding technologies have experienced a steep evolution in functionality, reliability, and ever-growing process and weld controllability, within widely interdisciplinary approaches and driven by demanding trends of Advanced Manufacturing (Industry 4.0). Technologic development can be optimized through basic research, which focuses on understanding the physical phenomena involved in metal transfer, weld pool behavior, and bead geometric formation and their correlation with each other and with the process’s variables. In this context, the objective of this work is to compare different waveforms of the short-circuiting MIG/MAG process with current control, namely CCC and SOFT, with the conventional process version, evaluating the influence of the electrical parameters on process stability and the general morphology of the weld beads. Analysis of metal transfer by means of high-speed filming and thermal analysis by infrared thermography supported conventional oscillographic monitoring for process characterization. Spatter emission assessment by means of image analysis was performed as well. The process’s versions with current control resulted in better operational weldability, geometric control of the bead, and lower spatter emission.