Journal of Manufacturing Processes 62 (2021) 283–290

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Journal of Manufacturing Processes

journal homepage: www.elsevier.com/locate/manpro

Dynamic analysis of the ultrasonic-frequency pulsed GMAW metal

transfer process
Zheng Hao, Qi Bojin, Yang Mingxuan*
Department of Materials Processing, School of Mechanical Engineering and Automation, Beijing University of Aeronautics and Astronautics, Beijing, China

A R T I C L E I N F O A B S T R A C T

Keywords: Current waveform control method was of great significance to welding quality of GMAW process. In order to
Current waveform control study the influence of a novel control method of ultrasonic-frequency-pulse on metal transfer process, a high-
Pulsed GMAW speed-camera was employed for droplet monitoring, and two image processing algorithms based on MATLAB
Ultrasonic-frequency
were proposed to extract the droplet size and position. Dynamic analysis based on pulsed GMAW in the mode of
Metal transfer
One drop per pulse
‘one drop per pulse’ was carried out. The results showed that compared with the conventional pulsed GMAW, the
Droplet velocity ultrasonic-frequency-pulse promoted droplet falling speed without changing droplet size under the same stable
condition, the droplet detaching mean velocity increased by 13 % at the maximum before the detachment, and
the droplet driving force in peak time duration increased by 19.9 % at most after the detachment. The study
helped to precisely control the pulsed GMAW metal transfer process.

Introduction
Gas metal arc welding (GMAW) was widely used in ocean engi­
neering, vehicle manufacturing, and pipe joining on account of its ad­
vantages of high efficiency and strong adaptability [1,2]. Industrial
automation was an important direction for the future development of
the manufacturing industry [3]. In order to meet the demands of
high-quality products, researchers had found that controlling the
welding current waveform was an important way to improve the
welding quality of GMAW process [4,5]. As a result, pulsed GMAW
(GMAW-P) became more and more popular in recent years for the ad­
vantages of the precisely controllable heat input [6,7], and one drop per
pulse (ODPP) was considered as the most stable mode of the GMAW-P
metal transfer process [8,9]. In addition, the droplet transfer process
had been seen as a research hotspot for a long time, it played a crucial
role in the welding quality [10].
Wang et al. [11] proposed that double pulsed GMAW had an
increased cooling rate, compared with conventional pulsed welding at
same heat input. Transfer modes of globular to spray transition current
and arc plasma variations features were acquired by Methong T et al.
[12]. Zhao et al. [13] found that the ideal square waveform with infi­
nitely steep-sided pulse would lead to a higher detaching speed and an
earlier detachment than other waveforms. Kang et al. [14] found that
the high peak current of the DC pulse increased arc stiffness and
enhanced droplet detachment. Zong et al. [15] provided with a double
shielded GMAW-P to feed the shielding gas of Ar and CO2 with two in­
dependent coaxial channels, they found that it could made the arc
heat-pressure distribution more concentrated and both the finger
penetration and undercut defect were suppressed. Chen at al. [16] used
the pulsed ultrasonic-assisted GMAW to reduce droplet size and increase
droplet frequency. Wu et al. [17] proposed a double-wire GMAW-P
process with a median current waveform, and found that the median
current had a significant impact on the metal transfer process. Metal
transfer had a great influence on the geometry of the welded joint [18].
Chen et al. [19] proposed an active control method for double-sided,
laser-enhanced GMAW, and found that the transfer frequency, droplet
size, and trajectory could all be adjusted in real time by the laser,
causing the metal transfer evolves into programmable transfer. Chen
et al. [20] studied the pulsed ultrasonic assisted GMAW, and proved the
ultrasonic radiation force was a determinant factor in arc compression
and droplet transfer acceleration. The appearance, microstructure,
microhardness, tensile properties, and impact toughness with three
typical modes of droplet transfer in pulsed GMAW (ODMP: one drop per
multiple pulses, ODPP: one drop per pulse, MDPP: multiple drops per
pulse) were studied and compared in detail by Zhai et al. [21].
As an important parameter of the metal transfer process, the droplet
velocity was not ignorable. Chen et al. [22] investigated the relation
between droplet momentum and penetration, and it was found that the

* Corresponding author.
E-mail address: yangmingxuan@buaa.edu.cn (M. Yang).

https://doi.org/10.1016/j.jmapro.2020.12.049
Received 17 September 2020; Received in revised form 18 December 2020; Accepted 19 December 2020
Available online 29 December 2020
1526-6125/© 2020 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
H. Zheng et al. Journal of Manufacturing Processes 62 (2021) 283–290

Fig. 1. UFP metal transfer process monitoring system (a), UFP-20 kHz (b) and four modes of current waveform control methods (c).

arc pressure was far less than the droplet impingement pressure. The
heat input and droplet impingement pressure per unit time acting on
weld pool were proportional to the current pulse frequency, which
fluctuated with thermal pulse. Jorge et al. [23] caught sight of the in­
fluence factors that governed weld penetration in GMAW was droplet
momentum and the wire feed pulsation.
The arc force, the arc core region ratio and the arc temperature could
be increased by ultrasonic-frequency pulse [24,25], it could also elevate
the molten pool temperature [26], eliminate the weld porosity [27], and
improve welded joint quality [28].
Above all, the results had shown the advantages of GMAW current
waveform control, and the importance of the droplet velocity to metal
transfer process. Therefore, it was vital to understand how the waveform
parameters control the droplet velocity, when the droplet impinging the
weld pool [29]. Hence, in this work, ultrasonic-frequency-pulse gas
metal arc welding (UFP-GMAW) was provided as a novel current
waveform control method, in order to research the influence of the
different current parameters on droplet dynamic characteristics during
metal transfer process compared with conventional pulsed GMAW
(GMAW-CP). Experiments and case studies based on GMAW-P in ODPP

Table 1
Current parameters of the welding power.
Conventional pulse UFP
Test No. Mode
Base-current/A Peak-current/A Peak-time/ms Frequency/kHz Amplitude/A Duty cycle/%

1 CP 40 250 / / /
2 10
3 20
PP 40 240
4 30
5 40
6 10
7 1.3 20
BP 30 250 50 20
8 30
9 40
10 10
11 20
AP 30 240
12 30
13 40

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H. Zheng et al.
Fig. 2. droplet barycentric coordinate and diameter algorithms.
mode were discussed.
Experiment procedure and method
Procedure and experiments
Fig. 1 was the UFP-GMAW metal transfer process visual monitoring
system (a), UFP-20 kHz (b) and four modes of current waveform control
methods (c). Fig. 1(a) showed the schematic diagram of the experi­
mental system for monitoring the UFP-GMAW metal transfer process. It
mainly consisted of two parts: welding system part, including UFP-
GMAW power source, wire feeder, shielding gas, welding torch and
the base metal, was proposed to provide with a stable welding condition.
Monitoring system part, including high-speed camera, ultraviolet filter
(UV), narrow band filter (NB), neutral density filter (ND), The near
infrared ray laser of 808 nm, PC, hall sensor and data acquisition (DAQ)
card, was used to acquire droplet visual information and welding elec­
trical signal. The UFP-GMAW power source was independently devel­
oped by Bojin Qi ultrasonic-frequency-pulse welding team, BeiHang
Univ., China. The welding power adopted advanced switching power
supply technology of ultra-fast transform square wave composite pulse,
which could realize 10− 100 kHz UFP current with amplitude between
0–100 A as shown in Fig. 1(b), it was an example of UFP waveform at 20
kHz captured by oscilloscope. There were four modes of UFP-GMAW
current waveform control method used in this paper as shown in
Fig. 1(c): Fig. 1(c-1) showed the conventional pulse (CP) mode, which
switched the peak and base current incessantly. Fig. 1(c-2) displayed the
peak-time pulse (PP) mode, which hybridized the UFP in the peak-time
duration of the CP mode. Fig. 1(c-3) illuminated the base-time pulse
(BP) mode, which hybridized the UFP in the base-time duration of the
CP mode. Fig. 1(c-4) was the all-time pulse (AP) mode, which hybridized
the UFP in all-time duration of the CP mode.
Table 1 showed the key experimental parameters of the welding
power source which embraced an adaptive arc length control strategy
[30], which the value of peak-current, peak-time and base-current were
fixed. However, the base-time depended on the real-time voltage
compared with the threshold voltage (18 V), it changed to ensure arc
length at the same value in the welding process. The high-speed-camera
was working at an exposure time of 3 μs and frame rate of 4000 fps. Laser
power was 0.529 W, 808 nm. The base metal was 2219 aluminum alloys
of 200 mm × 100 mm × 4 mm, the filler wire was 2319 aluminum alloys
with a diameter of 1.2 mm, and the wire feed rate was 7 m/min. The
welding speed was 600 mm/min. Pure argon was used as the shielding
gas, and the gas flow rate was 15 L/min.
Image processing algorithms
The metal transfer process contained 2 main stages [31]. One stage
was before the detachment from the wire (Before-Detachment stage),
including the wire melting, droplet forming and necking. The other
stage was after the detachment from the wire (After-Detachment stage),
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Journal of Manufacturing Processes 62 (2021) 283–290
including the droplet falling time across the welding arc. Based on
MATLAB, the images would be processed as follows:
Droplet barycentric coordinate extracting algorithm
Fig. 2(a) displayed the logic diagram of the image process. Step 1,
image preprocessing included turning the original map grayed and de-
noised using the method of median filtering. Step 2, the edge of the
wire and droplet was detected by ‘canny’ operator, which was one of the
most efficient computational theory to detect the true weak edge. In case
of breakpoints on the edge line, close operation was employed to erode
the image for connecting the breakpoint. Step 3, the regions of interest in
the Before-Detachment stage and After-Detachment stage were respec­
tively selected to highlight the feature areas and reduced the computa­
tional cost. Finally, barycentric and diameter algorithms mentioned
above were used for the droplet coordinate and diameter.
In the After-Detachment stage, the droplet had detached from the
wire and fell across the welding arc as an independent object, as it could
be extracted separately by selecting the region of interest (ROI) in the
image processing as shown in Fig. 2(b), the number of pixels nA, the
horizontal and vertical coordinate information of each pixel iA(xi, yi)
inside of the droplet could be extracted. Therefore, the droplet bar­
ycentric coordinate A(XA, YA) of the After-Detachment stage was sup­
posed to be calculated by Eq.1 and 2.
/
∑nA
XA = ( xi ) nA (1)
i=1
/
∑
nA
YA = ( yi ) nA (2)
i=1
In the Before-Detachment stage, the droplet was connected with the
wire, it’s not an independent object and not able to be calculated as the
After-Detachment stage. However, as shown in Fig. 2(b), the wire nadir
iB(xmin, ymin) could be extracted by counting the minimum vertical co­
ordinate valve ymin. Hence the droplet barycentric coordinate B(XB, YB)
of the Before-Detachment stage could be calculated, XB was equal to
xmin, and YB was ymin minus droplet radius.
Droplet diameter extracting algorithm
Globular hypothesis was used to calculate the droplet diameter, but
not all the falling droplet looked like an ideal ball. Therefore ‘crucifix’
algorithm was utilized to screen the globular droplet as shown in Fig. 2
(b). ‘Crucifix’ was composed by transverse axis for GAH and longitudinal
axis for FAE, which passed through barycentric coordinate A(XA, YA).
The ratio of short to long semi-axis was supposed to be above 87 % (eg. If
GA<AH, GA/AH>87 %): The ratio of short to long axis should be above
84 % (eg. If GH<FE, GH/FE>84 %). Then droplet would be more round
to support the globular hypothesis. Hence the screened droplet diameter
could be calculated by Eq. 3. S was the droplet area, which was equal to
n A.
H. Zheng et al. Journal of Manufacturing Processes 62 (2021) 283–290

acquired by Eq.5.
vi = (Ci+1 − Ci-1 )/2∇t (5)

Results and discussion

Fig. 4 showed the real-time electrical signal of the current-voltage

waveform and the corresponding droplet visualization under four
modes (CP, PP-10 kHz, BP-10 kHz, and AP-10 kHz). What UFP had in
common with CP were that: they both possessed stable welding pro­
cesses with nearly no spatter and fume. Similar patterns of the droplet
movement, frame 1–5 was the Before-Detachment stage, when the
droplet was formed and detached from the welding wire: frame 6–13
was the After-Detachment stage of droplet falling through the arc. Each
pulse produced a droplet, which worked in ODPP mode. Frame 10, the
droplet deformation declared the charge distribution of the droplet
surface was heterogeneous, though there’s less or no current flowing
through the inner droplet. And the arc column was diverging from the
welding wire to the base metal, which leaded to a diverging electro­
magnetic field. As a result, the droplet would be driven by the electro­
Fig. 3. Droplet velocity estimation method.
magnetic force. However, the UFP arc length was different from CP
√̅̅̅̅̅̅̅̅̅̅ mode macroscopically, meaning that there were various distances for
D = 4S/π (3)
Noticed that the droplet barycentric coordinate and diameter ac­
quired above was the pixel value, it could be corrected by the reference
of the welding wire (Diameter: 1.2 mm/37 pixels). Thus the actual value
could be obtained.

Droplet velocity estimation methods

As shown in Fig. 3, A series of scattered points (C1, C2, …, Ci, …, Cn-1,

Cn) could be acquired by the droplet barycentric coordinate extracting
algorithm mentioned in Section 2.2. The interval (∇ t) between each
points was 0.25 ms, it’s depended on the frame rate of the high-speed-
camera.
Thus the droplet mean velocity (vm) from Ci to Cn could be calculated
by Eq.4.
vm = (Cn − Ci )/[(n − i)∇t] (4)
Fig. 5. Droplet diameter value.
The droplet instantaneous velocity (vi) of Ci was supposed to be

Fig. 4. Real-time I-U curve and droplet visualization of CP, PP, BP and AP mode.

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H. Zheng et al.
Fig. 6. Instantaneous velocity of the Before-Detachment stage.
Fig. 7. Droplet mean velocity of the Before-Detachment stage.
the UFP droplet to get across, compared with CP mode.
The droplet diameter was an important index to evaluate the stability
of welding process [32]. It was generally considered that ODPP was the
most stable mode of GMAW, and the droplet diameter was uniform and
slightly smaller than welding wire diameter. As shown in Fig. 5, it was
droplet diameter value under different UFP hybrid modes and fre­
quencies. The diameter were calculated by the algorithm in Section 2.2.
The minimum diameter value (0.977 mm) appeared at BP-40 kHz, while
the maximum value (0.99 mm) appeared at PP-30 kHz. The values were
close to welding wire diameter, and the fluctuation range was 0.013
mm, merely accounting for approximately 0.1 % of welding wire
diameter. The results indicated that UFP hybridized and its frequency
had almost no influence on the droplet diameter and welding process
stability.
The process of the Before-Detachment stage
According to the barycentric algorithms, the coordinate information
of droplet could be extracted, then the axial instantaneous velocity of
droplet could be calculated. Fig. 6 showed the time-varying curve of the
droplet axial instantaneous velocity in various modes at 30 kHz in the
Before-Detachment stage. The I–U curve and images of CP mode were
shown as an example to help understand the synchronous process. The
droplet went across pulse base-current duration and peak-current
duration:
In Fig. 6, the pale yellow interval of 0.2–1.5 ms was the peak-current
duration, which presented the stage of melting the welding wire to form
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Journal of Manufacturing Processes 62 (2021) 283–290
Fig. 8. Droplet instantaneous velocity of the After-Detachment stage.
droplet. The detaching force would be increased because of the large
electromagnetic force provided by the peak-current, thus the detaching
process could be accelerated. Compared with the electromagnetic force,
the change scope of surface tension, plasma jet force, and gravity could
be ignored, so the droplet was accelerated downward in the peak-
current duration, the instantaneous velocity was increased approxi­
mately linearly. Interval of 1.5–2.5 ms was the base-current duration as
shown in Fig. 6 for droplet necking stage. Because the base-current
offered a small electromagnetic force, causing the surface tension
dominated as the maintenance force, leading molten metal to decelerate
the detaching process, the time-varying instantaneous velocity fell
approximately linearly.
Fig. 7 showed the trend of mean velocity variation under different
UFP modes and frequencies. The mean velocity of PP mode under
different pulse frequency was around 0.7 m s− 1, 0.7135 m s-1 at 20 kHz
was the maximum, and 0.6976 m s− 1 at 10 kHz was the minimum.
Fluctuation range only accounted for about 2.27 %, so the curve of mean
velocity of PP mode could be seen as a straight line, the results showed
that UFP had no influence on the mean velocity of the Before-
Detachment stage in PP mode. It’s because in PP mode, UFP was hy­
bridized on the peak-current duration for mainly melting the wire, only
affected droplet forming process and had little influence on detaching
mean velocity, and the mean velocities under the peak-current duration
were all about 0.65 m s− 1 by calculation under CP and UFP modes.
However there were significant mean velocity differences between CP
and UFP modes under the base-current duration, it mainly determined
the whole process of the Before-Detachment stage. Thus, two curves of
BP mode and AP mode basically coincided as Fig. 7, and the mean ve­
locity tended to rise with the increase of pulse frequency. In BP and AP
mode, the necking happened in the base-current duration with UFP.
Previous studies had shown that in UFP welding arc, the particles with
large kinetic energy would be affected by a large Lorentz force, and they
were forced to deflect to the center of the arc plasma, which would
create a region with a large absolute energy density [33], and the
droplet in the large energy density region would be driven by a larger
electromagnetic force. As a result, compared with the conventional
pulse, the UFP increased the droplet acceleration along the axial sepa­
ration direction and the mean velocity within the same time. It reached a
maximum of 0.7914 m s− 1 at AP-40 kHz, with an increase of about 13 %
compared with GMAW-CP.
The process of the After-Detachment stage
Fig. 8 showed the time-varying curve of the droplet axial instanta­
neous velocity in various modes of the After-Detachment stage at 10
kHz. When the droplet fell across the arc after it separated from the wire,
H. Zheng et al.
Fig. 9. Droplet peak-time acceleration of the After-Detachment stage.
the surface tension would be no longer the resistance force term.
Therefore, the axial instantaneous velocity increased with time. The
change of droplet velocity went through two stages:
The intervals between 0− 0.7 ms and 2–3.5 ms were the base-current
duration. During base-current time, the main promoting forces of metal
transfer were electromagnetic force and plasma jet force, which were
both relatively small. Hence the droplet velocity increased slowly. The
base-current duration was right arranged at the moment after the
droplet detaching from the wire, and the moment before entering the
pool. The arrangement could effectively reduce the unstable transfer
conditions caused by excessive electromagnetic force fluctuations, such
as spatter and fumes.
The interval of 0.7− 2 ms in Fig. 8 was the peak-current duration.
During the peak-current duration, the mainly promoting forces of metal
transfer process were pretty large, including electromagnetic force,
plasma jet force, leading to a much steeper instantaneous velocity
Fig. 10. Real-time I-U curve and arc visualization of CP, PP, BP and AP mode.
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Journal of Manufacturing Processes 62 (2021) 283–290
variation curve than base-current duration. The steeper slope during the
peak-current for average acceleration was shown in Fig. 9. BP mode was
in line with CP, had an acceleration growth of only 2.7 %. It’s because
the BP mode hybridized the UFP in the base-current duration, there was
no waveform change during the peak-current stage, so the electromag­
netic force during the peak-current stage had little effect on the accel­
eration. However, there’s UFP in the peak-current duration of PP and AP
modes, which brought greater electromagnetic force than CP mode at
the same current level, causing the accelerations of PP and AP mode in
the peak-current duration as shown in Fig. 9 with a significant accel­
eration amplification of 12.8 % and 19.9 % respectively.
Compared with CP mode, the instantaneous velocity of the After-
Detachment stage in PP, BP and AP modes were larger at any time as
shown in Fig. 8. By calculating the real-time velocity difference, The PP
mode had an increase of 0.157 m s− 1 on average, BP for 0.13 m s− 1, and
AP for 0.268 m s− 1.
The classical theory indicated the radial electromagnetic force
compressed the arc plasma with a large or pulsed current, the com­
pressed arc had more concentrated energy, and provided with a huger
electromagnetic force, which was supposed to offer a larger acceleration
and a significant amplification. When UFP was applied to the welding
arc, due to the high-frequency pulse electromagnetic effect, the transient
electromagnetic field would create the arc oscillation periodically in an
extraordinarily short duration. Macroscopically, the arc contraction in
shape could be processed, the arc energy was more concentrated, the
maximum temperature rose, and the arc force increased, leading to the
enhancement of the arc penetration and a higher energy transfer effi­
ciency. Microscopically, there were higher particles temperature and
faster particles dynamics inside the arc. Otherwise, the droplet in the
After-Detachment stage was inevitably motivated by the arc electro­
magnetic field. Fig. 10 showed the example display drawing of four
H. Zheng et al.
modes (CP, PP-10 kHz, BP-10 kHz, and AP-10 kHz) real-time electrical
signal of the current, voltage waveform and the corresponding arc
visualization. In the peak-time duration, the degree of arc contraction in
PP and AP mode obviously seemed lager than CP, while the BP mode had
the same level with CP. Because there’s UFP in PP and AP mode during
the peak-time current, whereas not in BP mode. Therefore, compared
with the conventional mode, PP mode had a greater acceleration in the
peak duration, BP mode had a greater acceleration in the base duration,
and AP mode had a greater acceleration at all time, so the instantaneous
velocity of AP mode was the largest at any moment as shown in Fig. 8.
Droplet transfer velocity had a decisive influence on penetration of
welded joint. The dynamic study of UFP droplet transfer contributed to
revealing the influence mechanism of the novel current waveform
control method in the welding process.
Conclusions
(1) The droplet formed in the peak-current duration and necked in
the base, the fast switching waveform precision control method
was able to effectively guarantee the welding stability for UFP-
GMAW. Compared with the conventional pulsed GMAW, UFP
had no influence on the droplet diameter and welding stability.
(2) During the Before-Detachment stage, the droplet mean velocity
was accelerated by UFP hybridized in the base-current duration,
which reached a maximum of 0.7914 m s− 1 at AP-40 kHz, with an
increase of about 13 % compared with GMAW-CP.
(3) During the After-Detachment stage, UFP could generate a larger
electromagnetic force on the droplet, increased the droplet falling
speed. By calculating the real-time velocity difference, compared
with CP mode, the PP mode had an increase of 0.157 m s− 1 on
average, BP for 0.13 m s− 1, and AP for 0.268 m s− 1. Furthermore,
the peak-current hybridized by UFP was able to increase the
droplet falling acceleration, with an increase of about 19.9 % at
AP-40 kHz.
Author agreement
We declare that this manuscript entitled “Dynamic analysis of the
ultrasonic frequency pulse GMAW metal transfer process” is original,
has not been published before and is not currently being considered for
publication elsewhere. We confirm that the manuscript has been read
and approved by all named authors and that there are no other persons
who satisfied the criteria for authorship but are not listed. We further
confirm that the order of authors listed in the manuscript has been
approved by all of us. The Corresponding Author is the sole contact for
the Editorial process, who is responsible for communicating with the
other authors about progress, submissions of revisions and final
approval of proofs.
Declaration of Competing Interest
The authors report no declarations of interest.
Acknowledgements
This work was supported by the National Natural Science Foundation
of China [grant number U20B2031, 51675031]; Beihang University
Postgraduate Innovation Practice Fund [grant number YCSJ-03-2019-
05];
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