Session 3: Advances in rc Wolling Processes )ATTERING MEASUREMENT DURING GMA WELDING OF AUSTENITIC AND DUPLEX. SAINLESS STEELS oson Feroke Cosa', Dando Bal! Fomandos', Edmundo Banedot!Fto!, Caraina Pimonta Loui Otvora Vian! Univers of Uberona poreoncsta@yahoo com br irrooucTiON Spatioring is charactaizod as undostabe melon material that does not contbute to the bead won. On the opposite, negatively contrbutes to beth quay and produc of the weidng ss Tua, satiering level canbe a parameter measure the proces eguaiy, pectealy the one ated to metal trance. In this case, low lve of spatrng Indicates good metabrantrreguaty and, bythe che hand, an nerease in spateing indeates @ mre eaic metal anst -Accorting to Bidar otal (198), the sparing generation is related othe woking process, a5 95 cere factors such a8 voltage and curent of wsding, shielding gas compostion, ave peed, horace of fle and base metal, a well a, the meta ranefer mode. For GMAW process, the ‘Shr eit transfor modo tends to generate more sptering when compared to oer modes. This is due tots mechanism of wanser, characterized by frequent conact between the metal drop formed atthe tip the etecroce wie and he fusion pul. nsdn, the amex of epaitenggenerion mayinerease en vations occur inthe me of short ecult and arc tne (Kang, 2003). In ther words, the spatter reration also depends on the eguarty of metal transfer and, according to Miranda (1000), this ‘opr suet for ow shot ut period and ow rater tine, wich leat smal and moe requent hops. In his context, ferent approaches have been proposed in the erature to astss the reguanty of he tater in GMAW process dung shortcut. Among hem, there ae the eta based on cent fd votage signals andlor in the number of shor-ckeuts and open arc, 38 wall a, in the amount of attering generation ‘There, this work aims to present a quantitative anayss ofthe lvel of sparing inthe Welding of austeitc and duplex stainless stots, using GMAW process with shortcut transfor. I is ‘oposed aso to corelate the spatering generation with an Index (Ma) that represent the regu in ‘he metal transfer. This index measured by montring the eecial signals (vcltage and cunt) and Isbased on the time of open and shortcut are, a8 wel a ints values of standard deviation, «‘Session &: Advances in Are Wing Processes For the quanttatve analyis ofthe level of spatioring inthe woking of austotic and duplox tars steals, the tests wore poformed according to previous pubcaton (Fernandes and Scott, 2008) ‘The main device the spatter collector, composed by a box formed by 8 square base chided ino three levels of range (vit 80 me, 81 fo 100 mm and above 160 mn), and hood, which fs to the base, bo made of copper n order to sort of spar by size, after the welding, a sto ree soves were used for separating the colecte sptters tin thre size groups of 50, 1.09 and 200m, “The teats wore cared out wih a constant-votiage power source for GMA with torch attached tw a robot unt for achieving repeatabty. The weld beads were made on 318" square bars of stainless stool AIS! OAL with 260 mm of longth, in simplowoling doposton. The wire alecrodo was ERSOSLS! (austenitic) and E2200 (Aino), both with diameter of 1.2 mm, suppiod by Sandvik Matoriie “Teeelogy. The chemical compostons can be foundin Tabs, 1 and2 provided bythe manufacture, Table 1. Chemical composition (% mass) of AWS ER3OGL (Sandvik, 2011) eae ee fon ator] nid ee fae [awes[~aa—[— 18 [20 [10 | Banas] ‘Table 2. Chomlcal composition (% mace) of AWS ERZ200L (Sandvik, 2011 ce oe NT oN aoa | os |-18-| 25 | 9 | -32 | 016 Bales ‘As specie parameters, it was varied the reference votage of 14,16, 1820 and 22 V, the wire- feed speed in 28 and 3.8 mini, the shielding gas (Ar¥2%60s and Ar+2%6CO:) ane CTIWD (contact ip to wertpece stance) mn order to mantain to ranges of welding cuent (120-1308 and 150-1608), Alter welding te spatiers were collected by using plastic bags, Ketled according tothe number ‘of tat bar and current range. A sale wih a raion of 001 g was used to obtin the inal and nal weights of tes bars and collotion bogs. For the caeutaton of metal transfer evenness index (Ma), used the Eq (1), whore “ote” isthe standard dovaton ofthe time of short rout, “otab le the standard deaton ofthe average te open ac, "ef the average time of short irc and "abi the average ime pen arc. W,=Sin Me, 13, RESULTS / DISCUSSION ‘The resus obisined from the anatysis of the collected spater, depziion eficlency and cleuition of Index of Regularity (Va) are shown in Figs and 2 forthe electode wire 308LS\ and 22001, respectively. Tho loss of maori (Ms) due to spateing generation i ow (xin of 3.5% of the melten materia, Consequent, the deposition effciency (7s high (above S54). The vttage eels| Session Advances in Are Welding Processes | that represent coniion sustabe for shoc-dreuttansfr, in which the requeny of sorte (Fa) fs 1} ower than the cutoff frequency (Fara) Preliminary tests show thatthe Far» for the adopted wires is .8 Geert evened 77H 20 nines | 8 me 4 CQ beese ft] | : rd | — 7 " + T | gut roa } af pa et vet | Figure 1 index of Regularity (Va), deposition efilency (qe) and mass of sparing (My). function of voltage for ERS0GLS! wire. The 1-1 dashed line nccats the highest vatage forthe } ‘cutoff frequoncy (Fars) Vth respect tothe Index of Reparity (Mex), i shouldbe emphasized thx: selon is fff tas te tie of ope ad shortest ae, slong wt respective andar devin, Thus, he H])—snater he varaton of tne bth open and state ae, the more regu is he mea waster Pp oprosorto by tho west ve of Ne. Souza (2010), sing GMAW process wt shot crc rater wel carbon st, noted thal he Index of Regt cuve has a feast ec and hen increase again its vale 2 a funcn ofthe wing votgeincoase When conpaing te ox of Repuirty (0) th he depstonefieney, Rezende eta. (2010) rte Hat the & a maximum fr the covet wit te minum Income forte Inde of Reply, ich wou be te best paramatic —‘Session 3: Advances in Are Weng Processes Figure 2 Index of Regularly (IV), deposition efficiency (2) and mass ofpattering (x) 28 function of voltage forthe ER2208 wire. The 18 dashed ine indicate the highest voltage forthe uot trequaney (Fem) In this conan wes expoctod that, for both the wees, the Behavior of he Index of Requay, a8 well sth correlation with the deposition efficiency curves (and amount of spatter generation), resemble tho results of erature for welding using carbon ste! wie. However, forthe wreslecrade ERSOBLSI tests (Fg. 1), ony in tests using wire-feed speed of 3.8 mimin and Ar+2%4COs showed ima behavie to 1 proper condton of shortcut transfer. It is possible to indicate the welding voltage, In wich the transfor is mor rogulr, is dain bythe nerescton of he Nu nd curves of pasion eclency. in this eae, tun out that fora votage of 16, the best ragulaty fs achieved wth the highest deposition fin and lowost sparing mass, However, a voltage increase, t reduces the regu ofthe rane. This reduces the deposition efciency and increases the lve of spate generation. (On the other hand, forthe other weling contons during the austenite wire case, iis not posse fo precisoly determin the vatiage levels with good regan. Ths, Fp 1, the 28 minin and |Aw/2%4CO: condition, good regulary i achoved for voltage values of 14 and 18 V. Fer condition 3.8 0‘Session 3: Advances in Are Welding Processes inn and Arv2%0, the voltage level of 18 V provided the best regulary, with behavior simi tothe ne that described by Souza (2010). However, the cuve of deposton efficiency ard spatering mass gs! ho NV curve dd not show a characterise vend, Simla behavior was founder the coneton of ‘28 min and Ar+2%O2, This canbe expainod by tho fat that ararow oporatonal ewelope was used |e. the employed condtons are in some extension prope fr woking, wit minor dflerences amng ‘tem Dierent rom the rests forthe austen (ERSOBLS) wire, the duplex (ER2200) wee presented an expected trond, easly observed in Fig. 2 with @ behavior sma Yo the resus ofthe work aay | montane, the lowe the IV value, the higher the deposition efficiency and the ewer the spatering nas, The Vex curves have paraboe beavis wth minimum point that indicates the votage leva, in ich the process operates wih bost metatransferreguaty, within proper conon of short et taster, ited by the cut-off frequency (Fam). AS wall as ther correlation i evident as the curves of eosiion efcioncy and mass of spate. In this cae, the depotiton efisoncy presented nage’ ofthe IV curve, Le, 25 the Ve daraases the depostonefsency ineease up o 8 maximum Fost. which coincides to the voage lave for the best reguanity (lowest pont ofthe Nix cue). The ear of spator generation curves (Ms) Isla to the Mc cues, Thus, for al the sesumptons topo, th intersection of cues indcatos the vltago range wth best regularly Ins case, the range sstom 410 18. The presented resus forthe Index of Raguarty (MV) and the mas of spaterng (My) were also assessed by using analyses of variance (ANOVA), depending on tho woking volage, as shown in Figs. 3 na, in thom Figure 3 Effect ofa) wir-feed speed and (b) shlong g of spattering Wr rocpoc tothe elect of wire fecd speed on mass of spate (Fig 3), should be note, hater both wires, there was no significant effect. Bu, there ea ght endency to redioe the amount of “ating withthe wirefeod speed inevease. Forte shiising ga, nether there was any significant ‘oc. Howover, thro is a trond, but ferent for each wre, a shown In Fig, 3). would be expected‘Sesson : Advances» Aro Welding Processes thatthe use of Shien gos wih CO: action increases the amount of sptterng generation compared to the addition of O: According to Cour 2008), the adeon of Os edices the surface tension of dopet transfer, factating the detachment and goneratng less sparing, whl, according to Bako and Data (2008), the largest CO; tamal conductviy at high temperatures promotes an imbalance of ‘lecromnagnatic ores acing on the drop during ts detachment, which leads to higher sparing. In this caso, the reels obtained for austniic wie show a tendency to incease he mass of spain using ‘xx#240COr, whereas forthe duplex a sight tendency to increase ofthe mas of satring to AZO: a! oy ‘| | : . { el By) 4 Baa | t ‘h Figure 4. Etec f(s) wirefeed speed a(t) shielding gas inthe Nec Win respect to the efect ofthese factors on Index of Regularty (Me), the rests showed sgnicant effects. In Fi. 4(0, or wirefeed speed of 28 min, the best regulaty of the transer fess {Na} was actiove. Fr the shildng gas (i. 4b), as wel as tho mass of spatirng generated was expected thatthe adtion of CO: could provide more regular meal transfer, when compared tothe addon of Os However, there was a totally opposte shun andthe gus isu of Ar¥2%CO> rested in ter regi: tt should be highlighted in Fig. 4 that there rnd of beter regularity of metal wansfe for the austenitic compared to wire duplex wie, depending on wirefeed speed and shielding gas. In general, the spattrng generation is concentrated most inthe region of knger range (upto +160 mm), maintaining a more homogeneous distribution forte other anges (up te 80 mm and 81 to 160, nn). As vltagenereaes, the concentration of spaterng close to the wad (up to 80 mm and 81 to 160, rn increases. This behaviors more pronounced forthe austenitic wi, as showin Fig. 5. On the or hand, or the duplex wie, such behaviors more crest (Fi. 6), and, na pti condition (refed speed of 28 minin and Ar+2%09), shown in Figure 6(), the debut of spt emsined constant for all votage eves ‘The spater tron by size coraboraes to what Is sready expects, ie, mater sptors tend to rach father distances. Thus, he incoase of welding votage tends fo generate larger spatter covert the welSession: Advances Are Weaing Processes Figure 6. Distribution of spattoring by reach to each welding voltage, referring te teste with wire 'ERSOBLS!, Va 2.8 minin, shielding gas a) Arv2%COs and (0) A240: z é i o San | Figure 6. Distribution of spattering by reach to each welding voltage, refering totests with wire 'ER2208, Va2.8 mimin, shielding gas a) Ar-2%CO: and (0) Are2Os, vate vate 4. CONCLUSION Generally the mate loss due to spatoring generation was low and depoaion efcincy was above 86%, For the duplex sanioss sal we, the lover regularly index value, the higher the deposition ficiency an the lower te patioring mass On the ctor hand, othe austenite sans toe wire, this tendency was not observed but can be explained ty the operational envelop used, which let stable‘Season : Advances in Are Woking Processes condo over the range, Weed speed and shsding gases presented sal influence on sparing generation for both wies, Hever, for regula Index, both variables hod significant ect. The regulty decreases 2s wirfeed speed increases and requ ls higher for Av2%CO2 and asteitic stainoss sta wir 5. ACKNOWLEDGEMENTS. The authors ofthis study woul ke to thank Laprosai/UFU (Center for research and development of woking processes the Federal University of Uberénca) fr laboratory infastuctre and technical suppor, the CNPq (for scholarship and Procs. 48197572012. and 20771072041), Fapemig (under Proc ‘TEC-PPM.00511-12), CAPESIPROEX and APERAM and SANDVIK for providng plates and electro 6. REFERENCES 1. Banda, J. Rubiovtz, S. Raman, 1980 “Development of a spatter inde for automated welding Irapocton using computer visor’. I Comput nd. Engng, Val. 18, No.2. p. 21-224, (Cabers. Disartaco de Mestad; UFU; Uberénda (Cer, Det, 2008 “Dlminucin del nive do salicadura en las sodacaa GMAW con la uizacion «do mezcias de CO2 + 02 como gis de protec’. Soldagom & Inspect, Séo Paulo v.11, p.34— 38, jntar Duta, J.C; Babo, C. EI; Olé, LF, Gohe Jnr, R. 1995. “InstumentacSo para Estudo da ‘Transferécia Metis em Soldagem GMAW por Cutout. In: XX! Encontio Nacional de ‘eenlogia da Sollagem, 1095, Casas do SuIRS, Anas do XX! Encoiro Nacional de Tecnologia da Soldagem So Paulo: Assoca;So Graalara de Scldagem,p. 867-888. Fernandes, D.B, Scot, A, 2008, “Procedimento para o Ensaio Laprosola de GeragSo de Furos em Soldagem GMAW, Versio Op. 1-12 6M. C. Rezende , 0, Uskéwch, LO. Vilainho, A. Scot, 2011. “Um Cro para Deteminar 9 Regulagem da Tensdo om Soldagem GMAW por Crt- Cults. Sotag, nsp. So Paulo, Vol 16, No.2, 058-108 Kang, M.; Kim, ¥:Ahn, 8. Rhee, S, “Spater Rate Etialon In The Shor-Cicit Transfer Region Of GMAW. Welding Journal, September 2003, Meanda, H.C, 1000. "intel da Indtnca na Soldagam GMAW ne Posigso Sobre Sancvk, 2011. Certcado de Qualifcago, Mogi Gua, So Paulo, Sout, D, 2010. “Levanta de Mapes Operacenais de Transfeénca Netilca para Soldagom GMAW de Ago ao Garbono na Poso Pana’ 304 p.DissertagSo de Mestrado— Universidade Federal e Uberineia, Uberti,