Modeling, Simulation and Control of Pulsed DE-GMA Welding Process for Joining of Aluminum to Steel

doi:10.3901/CJME.2014.0529.104

	Modeling, Simulation and Control of Pulsed DE-GMA Welding Process for Joining of Aluminum to Steel
	Zhang Gang; Shi Yu; Li Jie; Huang Jiankang; Fan Ding
刊名	CHINESE JOURNAL OF MECHANICAL ENGINEERING
	2014-09
卷号	27 期号:5 页码:978-985
关键词	pulsed double electrode gas metal arc welding dissimilar metals simulation and control particle swarm optimization
ISSN号	1000-9345
DOI	10.3901/CJME.2014.0529.104
英文摘要	Joining of aluminum to steel has attracted significant attention from the welding research community, automotive and rail transportation industries. Many current welding methods have been developed and applied, however, they can not precisely control the heat input to work-piece, they are high costs, low efficiency and consist lots of complex welding devices, and the generated intermetallic compound layer in weld bead interface is thicker. A novel pulsed double electrode gas metal arc welding(Pulsed DE-GMAW) method is developed. To achieve a stable welding process for joining of aluminum to steel, a mathematical model of coupled arc is established, and a new control scheme that uses the average feedback arc voltage of main loop to adjust the wire feed speed to control coupled arc length is proposed and developed. Then, the impulse control simulation of coupled arc length, wire feed speed and wire extension is conducted to demonstrate the mathematical model and predict the stability of welding process by changing the distance of contact tip to work-piece(CTWD). To prove the proposed PSO based PID control scheme's feasibility, the rapid prototyping experimental system is setup and the bead-on-plate control experiments are conducted to join aluminum to steel. The impulse control simulation shows that the established model can accurately represent the variation of coupled arc length, wire feed speed and the average main arc voltage when the welding process is disturbed, and the developed controller has a faster response and adjustment, only runs about 0.1 s. The captured electric signals show the main arc voltage gradually closes to the supposed arc voltage by adjusting the wire feed speed in 0.8 s. The obtained typical current waveform demonstrates that the main current can be reduced by controlling the bypass current under maintaining a relative large total current. The control experiment proves the accuracy of proposed model and feasibility of new control scheme further. The beautiful and smooth weld beads are also obtained by this method. Pulsed DE-GMAW can thus be considered as an alternative method for low cost, high efficiency joining of aluminum to steel.
资助项目	National Natural Science Foundation of China[51165023] ; Project of International Cooperation and Exchanges of National Natural Science Foundation of China[51210105024] ; Hong Liu Outstanding Talent Training Plan of Lanzhou University of Technology, China[J201201]
WOS研究方向	Engineering
语种	英语
出版者	EDITORIAL OFFICE CHINESE JOURNAL MECHANICAL ENGINEERING
WOS记录号	WOS:000341275500013
状态	已发表
内容类型	期刊论文
源URL	[http://119.78.100.223/handle/2XXMBERH/34293]
专题	材料科学与工程学院省部共建有色金属先进加工与再利用国家重点实验室
通讯作者	Shi Yu
作者单位	Lanzhou Univ Technol, State Key Lab Adv Proc & Recycling Nonferrous Met, Lanzhou 730050, Peoples R China
推荐引用方式 GB/T 7714	Zhang Gang,Shi Yu,Li Jie,et al. Modeling, Simulation and Control of Pulsed DE-GMA Welding Process for Joining of Aluminum to Steel[J]. CHINESE JOURNAL OF MECHANICAL ENGINEERING,2014,27(5):978-985.
APA	Zhang Gang,Shi Yu,Li Jie,Huang Jiankang,&Fan Ding.(2014).Modeling, Simulation and Control of Pulsed DE-GMA Welding Process for Joining of Aluminum to Steel.CHINESE JOURNAL OF MECHANICAL ENGINEERING,27(5),978-985.
MLA	Zhang Gang,et al."Modeling, Simulation and Control of Pulsed DE-GMA Welding Process for Joining of Aluminum to Steel".CHINESE JOURNAL OF MECHANICAL ENGINEERING 27.5(2014):978-985.