Delence Tecnology H (208) 28 Contents lists available at ScienceDirect Defence Technology journal homepage: www.elsevier.com/locate/dt Cold metal transfer (CMT) technology - An overview own S. Selvi **, A. Vishvaksenan *, E. Rajasekar ” * Mechanical Engineering. nie of Road and Tensport Technology, Erode, 638316, Tad India automo Engineering. nstnteof Road and Transport Technol. Erode, 638316, Trad. nia ‘ke stony old Metal Transfer technology has revolutionized the welding of dissimilar metals and thicker materials fetal bes at by producing improved weld bead aesthetic with controled metal deposition and tow heat-input. In ep ee {this study, the process, weld combinations, lse-CMTT hybrid welding and applications of CMT weding 2a critically reviewed, Microstructure and other weld characteristics have been discussed at length for ‘various base metal combinations Particularly the welding of aluminium an steel with better results has been possible with CMT Welding. The results reviewed in this article indicate that the CMT-Laser hybrid welding is more preferable to Laser or Laser hybrid welding. CMT welding has found applications in ‘Aeceped 18 August 2017 ‘Aalable online T September 2017 ieywos panes oe one automobile industries, defence sectors and power plants a a method of additive manufacturing ‘ecowt eae '© 2018 Published by Elsevier Ltd Tis is an open acces article under the CC BY-NC-ND license (hit) ‘dive manactsing ‘ceativecommons.oriicenses/by-ne-nd/400) Compost joie etal ner gs)6) etal ative gas} MAG] Contents 1. troduction Fa 2. Cold metal transfer process 2 3. CMT welding of similar metals 20 30 30 5:1, Inconel 718 alloy 32. Aluminium 7075 aloy 33, Aluminium AAGODI alloy = 31 34. Galvanized sheet stel 31 35, Galvannealed steel... 31 3.5, Alumina 5085-H16 alloy 3 37. Aluminium AATAS2 alloy. 38 AAIZIO-TESL ally. 4. CMT welding of disimilar metas... eee : a 41. Zine coated steel (Q235) and wrought aluminium (6061) 31 42, Magnesium AZ3T and aluminium 1060 alloy. coer 2 43, Magnesium AZ31 band and 6061 Al lly 3 44° Hot dip galvanized steel and aluminium 1060 alloy 4 45, Aluminium (AA6061) and low carbon steel alloy. 34 445, Magnesium AZ31 and hot dipped galvanized mild stel COUEEEEEIIIT, 4 47. Aluminium ASD61-TS and tam Ti-GAl-V alloys, 34 43. Aluminium AAGOGI-T6 to galvanized ste! alloy 35 48, Magnesium alloy AZ31B and pute copper 72 alloy eer errr 35 410, Pure titanium TAZ to magnesium alloy AZ31B alloy oe 35 11, SO83HIT1 and 6082-1651 aluminium alloys 36 * Coresponding suthor. mal addres slvnechOyshoo com (5 Sei Peer review under responsibilty of Cina Ordnance Society. uepedorg) 101016201706 002 22149147}0 2018 Pls by Eee Lt, This san open acess arte unde he CC BY-NC-ND Heese (h)xatvecommons.crgiensesy-ne-n.).Sele ol / Defence ecegy 14 (208) 28-44 29 412, Titanium TA2 to pure copper T2 alloy 36 413. Hot-dip galanized steel shoet and aluminium 5052 alloy 36 4.14. Aluminium 5A06 with pure NiN6 plates 7 136 415, 5182-0 and 6052-T4 aluminium alloy sets 36 416. Titanium AMSA9I1L with 316L stainless see 7 417. AGOGI-TG aluminium alloy to dual phase 800 steel 37 418. AC 170 PX aluminium alloy and STO6 2 galvanized steel Sheets a7 4419, 304 stainless steel and 506 aluminium allay sheet 38 5. Comparison of CMTand meta inert gas weiing 38 6. Laser-CMT are hybrid welding of metals a 0 GA Laser-CMT are hybrid welding of 12 copper “0 62. Laser ate hybrid welding of AAGOO1 alloy 0 63. _LaserCMT ate hybrid welding of s420 MCD, 0 7. Elect of base metal and CMT weld treatments 4 “LL Post weld heat treatment (PWHT) of CT weld a 72. Welding steel sheets treated by nitro-oniation using CAT process 41 ‘8, Alternative applications of cold metal transfer process : ae 31. Low-dilution cladding of INCONEL 718 superalloy a 82 Cladding f Al 06! alloy 2 83. Cold metal transfer deposited AZ31 magnesium aly clad. a 84 ALSéMn alloy coating ona commercially pure Al plate 2 85. Wetting of gadvanized stel by Al 4043 alloys 42 86 Weting of Mg AZ61 alloylgalvanized ste! in cold metal transer process 42 87. Additive manufacturing of AL5.3% Cu alley by CMT process “a 88. Composite-composte joints reinforced with cold metal transfer welded pins. ee 89. Crack repair welding of steam turbine cases by CMT brazing 2 9. Conclusions ‘a References “a 1. Introduction the appropriate CMT welding parameters forthe desired applica- Cold Metal Transfer welding is a modified MIG welding process based on short-circuiting transfer process developed by Fronius of ‘Austria in 2004, This process differs from MIGIMAG welding pro- cess only by the type of mechanical droplet cutting method not previously encountered (i). During welding, temperature varia- tions in welds and parent metals have important effects on material characteristics, residual stresses as well as on dimensional and shape accuracy of welded products [2]. Cold Metal Transfer pro- vides controlled method of material deposition and low thermal input by incorporating. an innovative wire feed system coupled with high-speed digital control [3 The wire feed rate and the cycle arcing phase are controlled to realise sufficient energy to melt both ‘the base material and a globule of filler wire |4)-There are two main features ofthe CMT process: one i at the point of short circuit with Jow current corresponding to alow heat input, another isthe short cireuit occurrence in a stable controlled manner. Kah et al. introduced the short-circuiting transfer process ‘named “mechanically assisted droplet deposition” which is applied in controlling short circuit by retracting the wire from short- circuiting [5]. Schier! reported that the droplet detachment mode fof CMT process is without the aid of the electromagnetic force compared to the conventional MIG process, so the spatter can decrease [6 Pickin and Young previously reported the basic ‘operating principles of the process |3]. Feng etal. pointed that the (CMT process i especially suitable for welding thin aluminium alloy sheets due to the fow heat input and the slight deformation {7}, ‘Additional studies by Zhang etal and Cag etal concentrated on the application ofthe process in dissimilar alloys joining owing to the low heat input, which restrains the formation of britle interme- tallic compounds (8. ‘A graphical interface was developed by Sonia Meco et al. using interpolation and neural network method to help the user select tion, by a graphical visualization of the welding profiles, which leads to time, material and cost saving | 10]. Amin S. Azar produced -aheat source model to simulate the effect of periodic and recurrent arcing and metal deposition phenomena in the cold metal transfer type of welding. This model will facilitate studying of weld pool behavior and resultant mechanical properties (|. Neutron imag- ing and Quantitative infrared analysis are some of the recent non- destructive tests performed on the CMT weld specimen |12.13]. A. required model for simulating the characteristic cooperation be- tween wire feeding and heat input was published by Fengyuan Shu etal. (14), 2. Cold metal transfer process In the CMT process, when the electrode wire tip makes contact with the molten pool, the servomotor of the ‘robacter drive’ ‘welding torch is reversed by digital process control. This causes the ‘wire to retract promoting droplet transfer which is depicted in Fig. 1, During metal transfer, the current drops to near-zero and thereby any spatter generation is avoided. As soon as the metal transfer is completed, the arc is re-ignited and the wite is fed for- ‘ward once more with set welding current reflowing [1] ‘Atypical CMT welding electrical signal cycle can be defined as, the period required to deposit a droplet of molten electrode into the ‘weld pool. The analysis of current and voltage waveform is essential to study the energy distribution of different phases in droplet twansfer process [15]. The cycle is divided into three phases as follows: (i) The peak current phase: This is a constant arc voltage cor- responding to a high pulse of current causing the ignition of the welding are easily and then heats the wire electrode to form droplet.Sele ol / Defence ecegy 14 (208) 28-44 29 412, Titanium TA2 to pure copper T2 alloy 36 413. Hot-dip galanized steel shoet and aluminium 5052 alloy 36 4.14. Aluminium 5A06 with pure NiN6 plates 7 136 415, 5182-0 and 6052-T4 aluminium alloy sets 36 416. Titanium AMSA9I1L with 316L stainless see 7 417. AGOGI-TG aluminium alloy to dual phase 800 steel 37 418. AC 170 PX aluminium alloy and STO6 2 galvanized steel Sheets a7 4419, 304 stainless steel and 506 aluminium allay sheet 38 5. Comparison of CMTand meta inert gas weiing 38 6. Laser-CMT are hybrid welding of metals a 0 GA Laser-CMT are hybrid welding of 12 copper “0 62. Laser ate hybrid welding of AAGOO1 alloy 0 63. _LaserCMT ate hybrid welding of s420 MCD, 0 7. Elect of base metal and CMT weld treatments 4 “LL Post weld heat treatment (PWHT) of CT weld a 72. Welding steel sheets treated by nitro-oniation using CAT process 41 ‘8, Alternative applications of cold metal transfer process : ae 31. Low-dilution cladding of INCONEL 718 superalloy a 82 Cladding f Al 06! alloy 2 83. Cold metal transfer deposited AZ31 magnesium aly clad. a 84 ALSéMn alloy coating ona commercially pure Al plate 2 85. Wetting of gadvanized stel by Al 4043 alloys 42 86 Weting of Mg AZ61 alloylgalvanized ste! in cold metal transer process 42 87. Additive manufacturing of AL5.3% Cu alley by CMT process “a 88. Composite-composte joints reinforced with cold metal transfer welded pins. ee 89. Crack repair welding of steam turbine cases by CMT brazing 2 9. Conclusions ‘a References “a 1. Introduction the appropriate CMT welding parameters forthe desired applica- Cold Metal Transfer welding is a modified MIG welding process based on short-circuiting transfer process developed by Fronius of ‘Austria in 2004, This process differs from MIGIMAG welding pro- cess only by the type of mechanical droplet cutting method not previously encountered (i). During welding, temperature varia- tions in welds and parent metals have important effects on material characteristics, residual stresses as well as on dimensional and shape accuracy of welded products [2]. Cold Metal Transfer pro- vides controlled method of material deposition and low thermal input by incorporating. an innovative wire feed system coupled with high-speed digital control [3 The wire feed rate and the cycle arcing phase are controlled to realise sufficient energy to melt both ‘the base material and a globule of filler wire |4)-There are two main features ofthe CMT process: one i at the point of short circuit with Jow current corresponding to alow heat input, another isthe short cireuit occurrence in a stable controlled manner. Kah et al. introduced the short-circuiting transfer process ‘named “mechanically assisted droplet deposition” which is applied in controlling short circuit by retracting the wire from short- circuiting [5]. Schier! reported that the droplet detachment mode fof CMT process is without the aid of the electromagnetic force compared to the conventional MIG process, so the spatter can decrease [6 Pickin and Young previously reported the basic ‘operating principles of the process |3]. Feng etal. pointed that the (CMT process i especially suitable for welding thin aluminium alloy sheets due to the fow heat input and the slight deformation {7}, ‘Additional studies by Zhang etal and Cag etal concentrated on the application ofthe process in dissimilar alloys joining owing to the low heat input, which restrains the formation of britle interme- tallic compounds (8. ‘A graphical interface was developed by Sonia Meco et al. using interpolation and neural network method to help the user select tion, by a graphical visualization of the welding profiles, which leads to time, material and cost saving | 10]. Amin S. Azar produced -aheat source model to simulate the effect of periodic and recurrent arcing and metal deposition phenomena in the cold metal transfer type of welding. This model will facilitate studying of weld pool behavior and resultant mechanical properties (|. Neutron imag- ing and Quantitative infrared analysis are some of the recent non- destructive tests performed on the CMT weld specimen |12.13]. A. required model for simulating the characteristic cooperation be- tween wire feeding and heat input was published by Fengyuan Shu etal. (14), 2. Cold metal transfer process In the CMT process, when the electrode wire tip makes contact with the molten pool, the servomotor of the ‘robacter drive’ ‘welding torch is reversed by digital process control. This causes the ‘wire to retract promoting droplet transfer which is depicted in Fig. 1, During metal transfer, the current drops to near-zero and thereby any spatter generation is avoided. As soon as the metal transfer is completed, the arc is re-ignited and the wite is fed for- ‘ward once more with set welding current reflowing [1] ‘Atypical CMT welding electrical signal cycle can be defined as, the period required to deposit a droplet of molten electrode into the ‘weld pool. The analysis of current and voltage waveform is essential to study the energy distribution of different phases in droplet twansfer process [15]. The cycle is divided into three phases as follows: (i) The peak current phase: This is a constant arc voltage cor- responding to a high pulse of current causing the ignition of the welding are easily and then heats the wire electrode to form droplet.Seb et b/c Tehoagy 14 (208) 28-44 2 conventional MIG and TIG processes and comparable to PSW and LBW processes (19) 33, Aluminium AAGO6! alloy ‘When Pavan kumar et al, welded thin aluminium alloy sheets, using filer, which is of same composition as of base metal, the weld exhibited @ quasi-binary composition. This composition is poten- tially less susceptible to solidification cracking, controlled fusion line, narrower heat affected zone (HAZ) and reduced intermetallic phase avea. The microstructures for different weld parameters seen in Fig. 6 revealed fine recrystallization at the joints. A uniform distribution of grains and its size in weld HAZ and base metal was dlistinely visible [20], 3.4, Galvanized sheet steel Joints of galvanized steel, made with electrode wire CuSis were Niobium carbide- Laves phase Fig. We ane of A 7075 ty. 160 150 140 130 120 110 100 90 QT 7s 13379 013 Hardneas/HV(1002) Fig. 5 Mcohardess proe at W2HAZ itera subjected to microscopic metallographic examination displayed in Fig. 7, which included both the weld zone and the base material ‘Macro- and microscopic metallographic examination by Magda et al. confirmed the high quality ofthe brazed joints, showing both the existence of a copper diffusion area and the undamaged zinc layer in areas adjacent to the weld [21] 35, Galvannealed steel Low and high heat input conditions had a tendency to less porosity formation in weld bead, whereas the medium heat input Conditions were the most susceptible to porosity formation. So- lidification started early in low heat input conditions, resulting in ‘small porosities near the weld root which are avoided in high heat input conditions |22|. Fig. 8 depicts the different porosity formation ‘mechanisms. Ahsan et al. developed optimized welding conditions to reduce porosity for two heat range inputs, one at low heat input ranging from 200 to 250 Jimm and the other at high heat inputs, starting from 350 jfmm and rising up to 550 Jfmm [23] 36, Aluminium 5083-H1I6 alloy Jair Catlos Dutra et al, used two different wire electrodes Al 5183, and Al 5087, Weld using Al 5087 electrode showed better me- ‘chanical performance in tensile tests. The miero-hardness was similar in both the WZ and HAZ, Practically, both wire-clectrodes showed the same toughness. Crack Tip Opening Displacement ‘Toughness test results indicate that the applied combinations of base and feed material yield good cracking resistance characteris: tics. ig. 9 displays SEM images, which illustrate higher incidence of pores with the Al 5183 wire electrode (24 3.7, Aluminium AA7AS2 alloy Feng etal. found that the intergranular segregation, which gave birth to the coarse grain boundary between the weld passes as depicted in Fig. 10, were indicated to exhibit inferior mechanical performances. Tri-axial stress distribution in the fusion zone was indicative of tendency to tensile failure under service conditions [25], The softened zone was much wider inside the base plates than lose to the flat surfaces. The strip-shaped quenched zone was ‘obviously narrower than the averaging zone internal plates 26) 38, AA2219-T851 alloy ‘A narrow finger-shaped geometry was observed by Cong Bao- «ang etal, using the conventional CMT process. There are a large ‘number of gas pores in the lower and upper parts of welds. Fis. 11 shows the weld microstructure in longitudinal direction using conventional CMT welding. The porosity was reduced effectively with the help of CMT welding [27) 4. CMT welding of dissimilar metals, CMT welding is also widely employed for welding of dissimilar ‘metals such as aluminium and steel. The novel dissimilar welds prepared using CMT are discussed below. 41. Zine coated steet (Q235) and wrought aluminium (6061) ‘The intermetallic layers formed at the interface between zinc coated steel and wrought aluminium are predominantly FeAls phase. Zhang et al. found that CMT increases the strength of the dissimilar metal lp joint by decreasing the thickness ofthe brite intermetallic compound at the interface between aluminium andSe eta / Defence enaagy 1 (208) 28-44 Peete Fig 6 Micostucturs af ASO alloy sen om Opti Moony steel. The toath like structure as displayed in Fig. 12, predominantly formed during solidification is mainly controlled by the diffusion of Fe and Al atoms at the interface between molten aluminium and solid steel The CMT welding of Q235 with AIGOG1-T6 by C2o et al. pro- duced strength equal to CMT welding of AIG061-T6 with AIG0G1-T6. ‘The joint strength was found to depend on the thickness of the intermetallic layer shown in Fig. 13, and softening ofthe Aluminium hheat affected zone 42, Magnesium AZ31 and aluminium 1060 alloy Wang et al. observed no weld defects as low heat input and addition of Sito the weld effectively inhibit the creation of brittle intermetallic compounds, which is checked using X-ray diffraction. is the fusion zone near the Mg substrate, which dictates the strength of the joint and its microstructure. Four continuous layers Fi 7. Brae weld one consisting of sold solution layer, eutectic structure layer, Mgi7Ali2 @ Cy ig 8. Poros formation mechanisms ioe est nts. ig. 9. SEM micrograph of atures ia weld ois usng S087 and S163 er wie,Sele ol / Defence ecegy 14 (208) 28-44 2 Fig. 1, Mirstruture of molten zoe. Fe 1. Weld microstructure in longue layer and MgzAls layer are observed. The micro-hardness in the fusion zone near Mg side is about 230-240 HM higher than the ‘weld metal 120 HM and the Mg substrate 60 HM 43, Magnesium AZ31 band and 6061 Al alloy ‘When Jing Shang et al. used pure Cu as filler metal, the inter- ‘metallic compounds AlCu, Cul, CusAly were present inthe fusion Sorte Reaction layer Fig 12 letra beeen well met an tee zone of Al side, and Cu based solid solution was generated in weld zone, while CusMg and Al-Cu-Mg ternary eutectic structure was {otmed in the fusion zone of Mg side. The bonding strength of the joint was 34.7 MPa, presents the fracture morphology. The Tracture occurred at the fusion zone of Mg side where the value of imicro-hardness was the highest due to large amount of CuMg, intermetallic compound ‘With ER4043 as filler metal, the CMT weld of AZ31B magne- sium and 6061 aluminium alloy developed by Shang Jing etal had uniform micro-hardness in both the sides of the substrate, about ‘540 MPa in Mg side and 350 MPa in Al side as seen in Fi. 16. The highest value of micro-hardness was 2380 MPa in the fusion zone ‘of Mg side, The micro-hardness in the weld from Mg side to Al side showed a decreasing trend with reduction of intermetallic com- pounds. The joint with low bonding strength was brite fractured in the intermetallic compound layer of the fusion zone of Mi side Intermetallic compounds of Mg2Si, MgyAl and MgirAly) distrib- ‘uted continuously in the fusion zone presented in Fis. 17, are responsible for the facture In the presence of AI-S%Si as filler metal, maximum tensile strength of 360 N/mm was achieved by Madhavan et al- Increase in tensile strength was attributed to minima tensile stress and finer precipitates. Improved pitting corrosion resistance was observed ‘ue tothe formation of Mg2Si and AlgMn in the interfacial layer. The ‘micrograph of the entire weld section can be observed in “Magnesium AZ31B and Al 6061 alloy was welded with Variable roc] Ce Onc ere Fig 14. Mirgraph of fson zoeFig 15, Facure morphology. Polarity CMT welding (VPCMT) by Peng Wang et al. The Mg~Al IMC layers were formed in the weld interface, near the AZ31B side of the welded joints and consisted of three intermediate layers: Mgols layer, MginAli layer, and MgizAlr2a-Mg solid solution eutecticlayer (very thin)as shown in Fig 19. With decreasing EP/EN ratio from 4:1 to 1:4, the thickness of the whole IMCS layer was gradually increasing and the tensile strength increased signi cantly, All samples were fractured in the hard brittle IMCs layer Welding of Mg AZ31B and Al 6061-T6 sheets yielded significant amount of Mg rich intermetallic compounds displayed in which degraded the weld strength at the side of Mg alloy base ‘metal, Both Madhavan etal. and Cao etal. obtained similar results for the above weld 44, Hot dip galvanized steel and aluminium 1060 alloy Zhang et al. noted that the compound layer at the interface between Steel and weld metal mainly consisted of FesAls and FeAls phase. Fig. 21 shows a SEM image of Steel-Weld metal interface. The thickness of the intermetallic compound layer was controlled un- der 5 jim guaranteeing the joint strength. The tensile strength arrived at was 83 MPa 2500 2000) Weid zone 1500 1000 Micto-hardness, HV/MPa 0 1 2 Distance from the center of weld jointimm Se eta / Defence enaagy 1 (208) 28-44 So Tee / . Fig. 17. Fusion zone, 45. Aluminium (AA6O61) and low carbon stel alloy Higher shear strength and fusion line failure were recorded by Jian Lin etal. when zine coating was provided to the steel sheet. Otherwise it led to lower shear strength and interface failure. The ‘maximum principle stress and deformation energy were proposed as the criteria for the interface failure and plastic strain was pro- posed as a criterion for the fusion line failure. Fig. 22 displays the interface between steel and aluminium 46. Magnesium AZ31 and hot dipped galvanized mild steet C20 et al. reported that the zinc coating on the surface of the steel is essential for a sound weld shows the brazing interface, which consists of Al,Zn, Mg intermetallic compounds and oxides (ie, MgFeAlO,, Fe2Os, and Mg22ny,) and a magnesium solid solution. Aluminium in the welding wie magnesium AZ61 en- hhances the wettability ofan Mg-rich weld metal on Zn-coated steel sheet 47. Aluminium A6061-T6 andl titanium Ti—GAI-4V alloys The IMCs at the brazing interface shown in mainly oT Ditfusi Fig. Weld ose sectionSele ol / Defence ecegy 14 (208) 28-44 ar pen} Fi 1, Wel incre composed of two layers: the continuous layer which consisted of ‘TiAl and TiAl close (Co the solid Ti alloy, and the discontinuous serration shaped TiAl; layer next to the weld metal. Cao et al observed fractures at the weldingjbrazing interface and weld ‘metal, and at the Al HAZ with most joints fractured in the latter mode. The tensile strength ofthe joint is high up to 194 Njmam 48, Aluminium AAGO6I-T6 to galvanized steel alloy Ie was found by Cao et al. that a sound joint could be obtained if the wire feeder speed is properly controlled. The brazing interface between the Al weld metal and galvanized mild steel was found t0 consist of about 5-8 ym thick FeAl, intermetallic. The micro- structure of the fusion zone is displayed in In addition, the ‘material stacking sequence affected the strength of CMT spot plug ‘welded joints. The strength of spot plug welded AABOGI joints was found to be lower than that of Al AA6O61-to-galvanized mild steel Joint 49, Magnesium alloy AZ318 and pure copper T2 alloy ‘The weld toe-brazing zone and weld root-brazing zone depicted in Fig, 26(a) and (c) respectively were similar and consisted of only fone IMC (MgizAlr2 > AlsCusMgs + a-Mg) layer. However, the in- termediate brazing zone observed in Fig, 26(b) consisted of two Fig. 21, Sto. metal eve ig. 22. tel tui itera IMC(MgaCu 4: MgCua + AlcCuaMgs and MgiAly + AlcCusMgs +: 0- ‘Mg) layers. When the thickness of the brazing interface layers be- tween the Mg weld metal and the Cu base were in the range of ‘80-350 mm, the lapped joint can reach higher strength of 172.5 N] ‘mm. It was concluded by Cao eta. that, in this range the thickness ‘of intermetallic brazing interface layers has no obvious effect on the tensile shear strength of the lapped joint 4.10, Pure titanium TA2 to magnesium alloy AZ31B alloy For Mg-TI joint, satisfied weld appearance and higher tensile Weld meta ‘A (@-Al solid solution) enn ey ATSOTTSltion a incrmeulics (ya Yt i aie lid sions TCM intermetallics (Al, Me,.) Mg Az31 H (@-Mg solid solution) Fie 20. Magi view o weld eos section and cmetponding schematic phate dts,6 Se eta / Defence enaagy 1 (208) 28-44 ig. 24. esznginertsebecween son joint an alloy matric load of 2.10 kN was obtained, For Ti~Mg.joint, a tensile load of 1.83 kN was detected. The brazing interface developed by Cao etal was mainly composed of TisAl, MgAlz and Mgos72No3 inter- ‘metallic Elements Al and Zn in the Mg base metal and Mg wite are crucial to join successfully Mg and Ti base metals (41). The weld interface of Mg/T joint and Ti/Mg joint are displayed in respectively, 4.11, 5083-HI11 and 6082-7551 aluminium alloys ‘The micro-hardness of the welded joints was similar to char- acteristic hardness traverse across weldments, hardness drops were slightly close to the base metal. The weld joints and base ‘metal had adequate tensile strength values shows the “Macrograph and SEM photos ofthe fracture surfaces ofthe Fatigue specimen, It was noted by Beytullah Gungor et al. that the CMT Welding results were closer to FSW, and had higher yield strength values than any other welding metlods 4.12. Titanium TA2 to pure copper T2 alloy ao etal. obtained satisfactory lap welded joints with desired, welding appearance and good wettability and spreadability of filler ‘metal on the surface of both alloys. A layer of IMCs, ie. TiCu, TiCu ig. 25, AAGOSI-TSte! asin zone and AlCuzTI were present in titanium-weld interface. The micro- structures of Ti-weld interface and Cu-weld interface are depicted in The tensile shear strength of the Joint I (top Cu sheet-bottom Ti sheet) reached 1975 N/mm while the tensile shear strength of the Joint Il (top Ti sheet—bottom Cu sheet) can reach 205.8 N/mm. The Join I and 1 had a comparable strength to CMT lap welded Cu-T2 to Cu-T2 with a tensile strength of 194 Nj ‘mm. The joints all fractured in the Cu HAZ with plastic fracture mode In CMT welding-brazing butt joint of Titanium TA2 to pure Copper T2 alloy by Cao eta, the thickness ofthe IMCs layer was not ‘uniformed: 117129 ym in middle groove surface and 80—100 jum 90 groove surface, are presented in respectively, ‘The IMCs layers a the brazing interface mainly consisted of Ti.Cu, TiCu and AlCusTI respectively from the Ti base metal to the weld ‘metal. Tensile loads 0f5.10 kN were reached, and fracture oceurred ar cu HAZ, 413. Hot-dip galvanized steel sheet and aluminium 5052 alloy Minjung Kang and Cheolhee Kim concluded that the Si composition ofthe filer metal primarily influence the thickness of the IMC layer. Using AISi (Al 4043 and Al 4047) filler wire, the _growth of the trapezoidal Fe,Als layer into the steel base materials, \was restricted, and anearly flat interface between the IMC layer and steel was observed. The specimens were fractured at the HAZ of the ‘Al 5052 alloy. shows the IMC thickness variation from the root 4.14, Aluminium 5A06 with pure NENG plates ‘The weld joint prepared by Liu et al can be divided into four parts: the nickel base metal; NisAl, NioAlys and NiyAly IMC layer; columnar NiAls layer; and AI-Si solid solution weld, as formed sequentially from the nickel side to the aluminium side. With an increase in welding velocity, the thickness of the IMC layer first decreased and then grev. This is depicted in ‘The greatest shear strength obtained was 42 MPa, The joint strength continued to decrease as the IMC layer thickened. The fractures were mainly located in the NiAl and NiAls IMC layer 4.15, 5182-0 and 6082-74 aluminium alloy sheets In the 5182 sheets, the HAZ microstructure showed fineSele ol / Defence ecegy 14 (208) 28-44 7 Fig 27. Weld inte of Ma joint ig. 28, Wold trace of TIM oi precipitates of second phase and coarsening of the MgoAls pre- Gipitates in the aluminium matrix. in general, it was found by ‘Ahmed Elrefaey and Nigel G. Ross that CMT welding of 51826082 alloy did not show worse mechanical properties compared to S182/ 5182 and 6082/6082 joints. Fig. 35 displays the weld zone images of 5182/6082 weld Fig 28, Fracture sre of atgue specimens. 416, Titanium AMS4911L with 3161 stainless steel Goncalo Pardal et al. obtained maximum tensile properties at higher heat input. The IMCs formed are more ductile in nature ‘when compared to the Fe-Ti IMCs and were mainly located at the interfaces between the parent metals and the Cu (filler wire). The maximum hardness measured was 1000 HVO.1. The weld interfaces are presented in 4.17, A6061-T6 aluminium alloy to dual phase 800 steel ‘The grains in nugget zone near HAZ coarsened and the Mg2Si phase dissolved, which resulted in Al softening and as a result, the joint strength was reduced. Madhavan etal, discovered the pres- tence of the Fe3Al and FepAls phases in the weld nugget from the XRD and electron microscopy analysis. Thickness of the IM layer ‘een in Fig. 37 varied from 1.49 to 3 mm for the P-CMT and CMT processes respectively. At the interface, fi-FeAls and g-FeaAls pha- ses were formed, The CMT and P-CMT welds failed at the Al HAZ This failure mode has ductile fracture characteristics with dimples and voids 4.18. AC 170 PX aluminium allay and STO6 Z galvanized stel sheets ‘The thickness of interfacial layer was only 0.6 jm. The tensile shear strength reached 189 MPa which is 89% of the aluminium alloy base metal. The spalled needle-like IMCs visible in ‘were confirmed as Al-Fe-Si ternary intermetallic compounds bySe eta / Defence enaagy 1 (208) 28-44 @) o Fi 30. Microsc of 2 Tewedimerfce and b) Cu-Wea irae Fig. 31, idle surtace of bang ner Weld metal Fi 32, Roo sure o brazing interac -| a= Aluminized seal/4 093 filler =O= Aluminized steel 047 filer Se Aluminizedstee’5 183 filler 30 =o= Aluminizedstel/5 336 filler T= Aluminizedstel4 047 filer —S Aluminized steeVs 183 filler IMC thickness/im 0 1 Sasa ene) Distance from root/mm Fig. 32, Variation of thickness acoding ote IMC Song Niu etal, which had negative effect on tensile strength of the joint. With increasing welding cutrent, the needle-like IMCs grew Tonger and spread further into the weld, reducing the tensile shear strength ofthe joint 4.19. 304 stainless steel and 5A06 aluminium alloy sheet Under the effect of an axial EMF, both the welding are and the ‘molten drop were rotated by Lorenz force. The EMF influenced the ‘growth of the Al/Fe IMC layers during Alfsteel welding, Under EMF application, the diffusion of Fe to the weld was suppressed and the Si content in the IMC layers increased, which restrained the growth of brittle Al/Fe IMC phases. Fis. 29 contrasts the difference observed while applying an axial EMF during CMT process. Yibo Liu et al found that the application of the EMF inereased the tensile shear force of the weld joint. AC EMF frequencies of O Fiz and 5 He, stronger joints were obtained, and within crease in coil current, the joint strength increased even further 5. Comparison of CMT and metal inert gas welding, “The tests conducted by Mateusz Greybicki and Jerzy JakubowskiSele ol / Defence ecegy 14 (208) 28-44 Fig. 36, Sela and Cu weld inteticeSe eta / Defence enaagy 1 (208) 28-44 o » Fig 37.3) EM) TER amage of ayer shows that compared to traditional MIG variety welding, the CMT ‘method has several advantages such as low energy, spatter fe, high welding speed. It also enables the welding of thin sheet metals. However, there is a great danger of incomplete fusion. especially for lap joints which could he avoided by increasing the arc length (52). The CMT welding by Jair Carlos Dutra et al. showed ‘more stability and the root produced showed a good finish, both on the surface and back of the joint than the conventional MIG welding [53) ——t << Fig. 8, AUSTOO Z te wed ine 10m @ 6, Laser-CMT are hybrid welding of metals 64. Laser-CMP arc hybrid welding of T2 copper Yulong Chen et al, achieved continuous and regular welds at a ‘minimum power of 2 kW, which is very much less than the mini- ‘mum power level of laser welding (about 5 kW). large amount of, Si-ich precipitates were found in the Fusion Zone (F2) grains of the hybrid welds, which caused the FZ of hybrid welds to be harder than laser welds. Fig. 40 shows the Si-tich precipicats in the FZ of the hybrid welds. The UTS, YS, and the Elongation of the hybrid weld with the best performance were up to 227 MPa, 201 MPa, and 21.5%, respectively. The decrease of the porosity was the main reason for strengthening of hybrid weld [54 62. Laser-CMT arc hybrid welding of AA6O6I alloy Laser-CMT hybrid welding was developed to join 2-mm thick |AAGOS! Al alloy by Zhang et al. Acceptable joints without metal- lurgy defects were obtained. The cross-weld tensile strength of laser-CMT hybrid welds was up to 223 MPa, 10% higher than that of the laser-PMIG hybrid weld. Fig. 1 shows the microharciness dis- tributions of transverse joints. The results showed that laser-CMT hhybrid welding could potentially join aluminum alloy thin sheets. Fig. 42 depicts the equiaxed dendrites in the center of the weld fusion zone (55) 63, Laser-CMT arc hybrid welding of $420 MC D Jan Prostovarg et al. compared the hybrid weld with a close-to- predluction setup for low and medium wire deposition rates Fig. 3 104m »Sele ol / Defence ecegy 14 (208) 28-44 a ig. 0. Precipitates in FZ of id wel displays the High-Speed Image of laser arc hybrid weld pool. They concluded that the CMT is suitable for laser hybrid welding of thicker sheets provided the gap is narrow enough to be filled by the limited wire feed rate. The hybrid weld showed advantages of higher bead stability, reduced undercut, reduced power supplied, reduced weldj/HAZ width and less sensitive to speed variations [56 7. Effect of base metal and CMT weld treatments 71, Post weld heat treatment (PWHT) of CMT weld The effect of PWHT on the mechanical and microstructure properties of welded AAGOGI using the CMT GMAW was analyzed by Ahmad and Bakar. In their investigation, 3.8% increase was recorded for tensile strength as observed in hardness strength was increased by 25,6% and a 21.5% higher elongation was achieved. The results proved that PWHT was able to enhance the hardness strength and tensile properties of AAGOG1 welded joints using the GMAW CMT method. These were attributed to the fact ‘that PWHT produces afine and uniform distribution of precipitates at the weld joins 72, Welding steel sheets treated by nitro-oxidation using CMT process The limited heat input and the controlled metal transfer, which 110 100 f Heat affected %0 Base metal 2 80 2 70 Hi . = 10 oe 1G ay Distance to the weld center/mm ig 4 zohan ston ig. 42. quae denies inthe cone othe Fig 43, High Spee image of Laser Arc hybrid weld pod are considered as the main advantage of the CMT process, had a negative impact on weld joint quality. An excessive amount of porosity was observed, probably due te the high content of nitrogen, and axygen in the surface layer ofthe material and the fast cooling rate of the weld pool. The results show that for steel sheets treated by nitro-oxidation there was a radical increase in micro hardness values, up to 47%, in comparison with the values for the same ‘material without surface treatment. After CMT welding, it was ‘observed that the microhardness values gradually declined from the weld metal til the heat affected zone, stabilizing in the base ‘metal as seen in Fig. 45. The parameters of the CMT process per- formed by Michalec and Maronek were not suitable for welding, steel sheets treated by nitro-oxidation, due to the high level of porosity 53.314 coeee Tensile strengtivMPa As-welded Heat treated ig. 4. Teste strength oa welded an eat-reated same,2 Se eta / Defence enaagy 1 (208) 28-44 ‘8 Alternative applications of cold metal transfer process 811. Low-ailution cladding of INCONEL 718 superalloy ‘Microstructural study of INCONEL718 superalloy lad by Ola and, Doetn revealed that the clads were free from porasity and cracking, and complete bonding of the clads withthe substrate was achieved in all weldments. The outcome ofthis work showed that the rela- tively new CMT process, with the choice of suitable welding pa- rameters, is useful for repair buikl-up of affected areas of worn-out and service damaged components of gas turbines and other high- temperature equipment that are manufactured from nickel-base superalloys [59)- 8.2. Cladding of A 6061 alloy Benoit et al. performed Al 6061 clads using Metal inert gas, (MIG), pulsed MIG, cold metal transfer MIG (CMT) and tungsten inert gas (TIG) welding, The cladding operations were analysed by an infrared thermal imaging technique and beads were character- ized by X-ray radiography, neutron diffraction and micro-hardness ‘mapping. The Pulse-Mix CMT process reached higher peak tem- perature and produced better quality beads than other MIG pro- cesses. The level of residual stress present in the HAZ of the CMT sample was the highest (60) 83. Cold metal transfer deposited AZ31 magnesium alloy clad Cold metal transfer (CMT) with low heat input exhibits a great potential for magnesium alloys welding as they are susceptible to ‘grain coarsening, pores and hot cracking during welding. In this paper, Heng Zhang et al observed the effect of welding speed on microstructures of CMT deposited AZ31 magnesium alloy lad, The results demonstrated that t0 get a qualified cladding of AZ31 ‘magnesium alloy, pulsed-CMT, with an optimal welding speed of 12 mmjs, was preferred [61 84. AL-Si-Mn alloy coating on a commercially pure Al plate ‘The CMT process can be used as an energy-efficient technique for depositing thick coatings and is useful in weld repair of aluminum alloy components. Rajeev etal. reported that the bead angle, deposition rate and dilution are nonlinear functions of the Welding speed. Their coating had thickness greater than 2.5 mm produced in a single pass, which is considerably high compared to thermal spray processes [62 260 240 220 200 180 160 140 120 100 HVO,1 WM HTHAZ HAZ BM Fig. 45, Merotardess ves ed 85, Wetting of galvanized stel by AI 4043 alloys Yanlin Zhou and Qiaoli Lin performed the wetting of galvanized steel by 4043 AI-Si alloys under CMT condition and studied the interfacial structure. Th final wettability ofthis system was mainly determined by the wettability of Fe by Al (or steel by AD. The re- sidual liquid Zn film after evaporation cannot improve the final ‘wettability, and also should not be a driving force for spreading but ‘may be a factor forthe contact angle hysteresis. Further, the moving of the triple line (ie, spreading) in this system was limited by the viscosity ofthe liquid itself [63]. The beneficial role of Zn coating is the reducing of the heat input, and a thinner intermetallic ayer can be obtained [6 Qiaoli Lin et al, found that for small wire feed speed, the Leidenfrost effect was caused by Zn vaporization which duced the non-wetting and welding splatter. The wettability was improved using large WFS [65,56]. 86. Wetting of Mg AZ61 alloy/galvanized steel in cold metal transfer process ‘The dynamic sessile drop method was used by Qiao Lin etal. to Investigate the wetting behavior of galvanized steel by molten Mg ‘AZ61 alloy under cold metal transfer condition. The observed re- sults showed thatthe wetting behavior was directly determined by the wire feed speed (or the heat input) (97) 87. Additive manufacturing of AL-6.3% Cu alloy by CMT process Baogiang Cong presented a paper on the effect of arc mode in, cold metal transfer (CMT) process on the porosity characteristic of additively manufactured Al-6:3%Cu alloy. Experiments were per- formed on both single layer deposits and multilayer deposits. The variants of CMT performed in the experiment were conventional CMT, CMT pulse (CMT-P), CMT advanced (CMT-ADV) and CMT pulse advanced (CMT-PADV), CMT-PADV proved to be the most suitable process for depositing aluminium alloy due to its excellent per- formance in controlling porosity. The key factors which enabled this are low heat input, a fine equiaxed grain structure and effective oxide cleaning of the wite (08), 88. Composite-composite joints reinforced with cold metal transfer welded pins Stelzer et al performed fatigue tests on both Ti CMT and Stee! CMT pins used to reinforce Carbon Fibre Reinforced Polymer (CFRP) sheets. Cold metal transfer welded steel pins proved to be an effective means for reinforcing CFRP—CFRP SLS joints in the through-the-thickness direction. After failure of the bond line be- tween the two CFRP laps, pins earry the loads and maintain the joints stiffness until final failure, CMT welded titanium pins on the other hand turned out tobe less effective in reinforcing CFRP-CFRP joints. This can be partly ascribed to the lack of a pronounced ballhead-spike geometry for Ti CMT pins (69). 8.9. Crack repair welding of steam turbine cases by CMT brazing, Cold metal transfer welding was investigated by Kota Kadoi etal. to develop a repair process for cracks in steam turbine cases, ‘made of Cr-Mo-V east steel, operated for 188,500 h at 566° C. Silver and gold brazing filler wires were used as overlaying, materials. CMT brazing using low melting point filler wire generally was found to decrease the heat input and peak temperature during the thermal cycle of the process. The creep-fatigue properties of weldments produced by CMT brazing with BAg-8 were the highest. ‘Therefore, CMT brazing using low melting point filler wire such asSeb et b/c Tehoagy 14 (208) 28-44 o [BAg-8 is a promising candidate method for repaiing steam turbine cases (70). ‘9. Conclusions ‘The process, weld combinations and applications of the Cold Metal Transfer welding reported by various authors are discussed. ‘The main conclusions of this study are: 1) The retraction ofthe wire during the shor circuiting phase plays an important role, as it leads to prevention of spatter generation and also produces better weld bead aesthetics. 2) The Laset-CMT hybrid welding produces welds with better ‘mechanical properties and aesthetics than the Laser welding and Laser-MIG hybrid welding. 3) The Post Weld Heat Treatment (PWHT) caused a positive effect ‘on the welds prepared by uniformly distributing the fine pre- cipitates, whereas the Nitro-oxidation treatment of the base ‘metal prior to welding caused an increase inthe level of porosity ‘causing a drastic increase inthe microhardness of the weld, 4) The Cold Metal Transfer Welding has a wide variety of appli cations such as cladding, additive manufacturing. composite {int pin fabrication, and crack repair welding. 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