• Journal of Welding and Joining
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• v.13 no.4
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• pp.85-102
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• 1995

Weld quality of GMA welding processes is closely related to arc stability. Although many researches on arc stability have been performed, real-time estimation of arc stability has not been attempted. For instance, Mita proposed a off-line statistical method in which short circuiting and arcing time, and voltage and current wave forms were sampled to assess arc stability. But this method is not suitable to assess arc stability for GMA welder which employ inverter power source due to its controlled current and voltage wave forms. In this paper, the relationship between are stability and wire feed rate fluctuation is analyzed to propose new criterion for inverter power source. When arc voltage and arc current and arcing time are analyzed, we can assess arc stability only for short circuit transfer mode. When wire feed rate is analyzed, we can estimate arc stability udner the condition of spray transfer mode as well. Hence, the wire feed rate is chosen for monitoring process variable to cover possible metal transfer modes in GMAW. Through this research, it has been identified that arc stability in GMA welding processes is closely related to wire fed rate. When inverter power source is used, conventional statistical method of estimating arc stability, such as Mita index, is no longer valid due to its controlled voltage and current wave forms. Arc stability has been also examined in phase plane diagram.

• Journal of Welding and Joining
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• v.8 no.1
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• pp.31-42
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• 1990

Arc must be stable during welding first of all other factors for obtaining sound weldment, especially in the automation of welding process. Arc stability is somewhat sophisticated phenomenon which is not clearly defined yet. In consumable electrode welding, the voltage and current variation due to metal transfer enables to assess arc stability. Recently, statistical analyses of the voltage and current waveform factors are performed to assess the degress of arc stability which is assessed and controlled by operator's own experience by now. But, considering the increasing need and the trend of automation of welding process, it is necessary to monitor arc stability in real-time. In this sutdy, the modified stability index composed of two voltage and current wvaeform factors (arc time and short circuit time) reduced from four factors (arc time, short circuit time, average arc current and average short circuit current) in Mita's index by the welding electrical circuit modeling is proposed and verified by experiments to be well estimating arc stability in the static sense. Also, the recursive calculation form estimating present arc stability in the dynamic sense is developed for real-time estimation. The results of applying the recursive index during welding show good estimation of arc stability in real-time. Therefore, the results of this study offers the mean for real-time control arc stability.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.12
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• pp.152-160
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• 1999

The weld quality of $CO_2$ arc welding is closely related to the arc stability. As the characteristics of the arc are excessively complex and nonlinear, it is not easy to make the arc model as mathematical form and to control the arc state to be stabilized. This paper was aimed to estimate the arc stability and to control for stabilizing the arc state in short circuit metal transfer mode of $CO_2$ arc welding. For these purposes, the behaviors of arc stability was investigated at different welding conditions using Mita's arc stability index, and the fuzzy control algorithm which uses the arc stability index as control imput and the arc voltage as control output was developed. In the control of the arc stability, the experiments of two cases were performed; the case of setting an initial welding voltage arbitrarily, the case of the step change in workpiece shape. Obtained results were as follows; Mita's arc stability index was able to be estimated qualitatively in the case of using the inverter type welding power source and the control performance for stabilizing the arc status was excellent in the case of existing step change disturbance.

• Proceedings of the KIPE Conference
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• 2011.07a
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• pp.498-499
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• 2011

In this paper, the fundamental features of the arc stability DC arc furnace have been investigated, from the converter point of view. To compare of measurement arc data from DC arc furnace and the advanced arc simulations of magneto-hydrodynamics (MHD) and the well known Cassie-Mayr arc model have been extensively used. The MHD based arc simulation has been validated in the subcomponent level, for the free burning arc set up in the laboratory. The arc simulation predicted the arc voltage for different currents with the accuracy which satisfies engineering requirements. It has been shown that the arc current steepness at current zero determines the arc stability, and the associated peak arc resistance can be used as its quantitative measure. Based on the presented insight into the DC arc stability, a converter topology solution which realizes an optimal arc stability has been proposed. The main results presented in this paper provide a design guideline for the future DC arc furnace converter topology developments.

• Proceedings of the KIPE Conference
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• 2012.07a
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• pp.371-372
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• 2012

In this paper fundamental features of the arc stability in DC arc furnace of 720V/100kA/72MW have been investigated. Cassie-Mayr arc model has been employed for the target dc arc furnace. In order to characterize the parameters of Cassie-Mayr arc model and the behavior of unstable arc dynamics, the advanced arc simulations of magneto-hydrodynamics (MHD) has been performed. Based on the results of MHD simulation, dc arc dynamic resistance is proposed to be an effective arc stability function reflecting the instability of dynamic arc behavior. The experimental result confirms the usefulness of proposed dynamic arc resistance as arc stability function. The proposed arc stability function can be regarded as an effective criterion for the overall power conversion system to maintain highly stable arcing operation leading to better productivity and reliability.

• Journal of Welding and Joining
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• v.16 no.4
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• pp.125-135
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• 1998

The shielded metal arc welding (SMAW) by AC power source was performed to evaluate the arc stability by arc monitoring and analysing. In this study, the arc stability index was evaluated quantitatively by using he coefficient of resistance variation for welding time. This coefficient was obtained for the long time (20sec.) by analysing the waveforms of welding current, voltage and resistance. The coefficient was applied to indicate numerically the variation level of arc length and the degree of arc extinction. Using the coefficient of resistance variation in practical welding, the arc stability of the high titanium oxide electrode (KS E4313) turned out to be better than that of the low hydrogen electrode (KS E4316). In evaluating the skill level of welders by the coefficient, the horizontal fillet weaving welding became clear to be very discriminating because the higher level welder could weave in keeping constant arc length, but the lower level welder showed the characteristics of weaving with the unstable arc length. And it was confirmed that the welding defects as blow holes was formed when the arc stability index were high.

• Proceedings of the KIPE Conference
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• 2013.07a
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• pp.354-355
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• 2013

Fundamental features of the arc stability in DC arc furnace of 720V/100kA/72MW have been investigated. Cassie-Mayr arc model has been employed and applied for the target dc arc furnace. In order to characterize the parameters of Cassie-Mayr arc model and the behavior of unstable arc dynamics, the advanced arc simulations of magneto-hydrodynamics (MHD) has been performed. The MHD based arc simulation has been validated in the subcomponent level, for the free burning arc set up in the laboratory. From the results of MHD simulation, dc arc dynamic resistance is proposed to be an effective arc stability function reflecting the instability of dynamic arc behavior. The experimental result confirms the usefulness of proposed dynamic arc resistance as arc stability function. The proposed arc stability function can be regarded as an effective criterion for the overall power conversion system to maintain highly stable arcing operation leading to better productivity and reliability.

• Journal of Welding and Joining
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• v.15 no.6
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• pp.41-48
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• 1997

For analyzing the characteristics of arc welding processes, an algorithm is necessary to determine the metal transfer mode, arc stability and weld quality. In this study, the weight of spatter during welding was selected for determining the arc stability, which is very relevant to the occurrence of spatter. Weld spatter occurs mainly at the moment when the short circuit is formed and also when it is broken causing the arc to restrike. Based on this fact, the arc stability can be determined by finding the suitable parameters of welding current and arc voltage which influence the weight of spatter. Through various welding experiments, the peak current, the arcing time, the short circuit time, the current and its slope at the start of short circuit were found mainly to influence the weight of spatter. For the convenient usage, an index was proposed by combining all these parameters. It was found that the index is very effective for determining the arc stability.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.8 s.179
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• pp.1885-1898
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• 2000

Welding quality is closely related to the arc state. So, it is very important to estimate the arc state in real time. In the short circuit transfer region of CO2 are welding, the spatter , as it is well known, is mainly generated on an instance of short circuit or on an instance that the are is ignited after short circuit, or on the cases of an instantaneous short circuit. If the short circuit period or the arc time is irregular, the spatter is generated more than it is regular. Thus there is a close relationship of the amount of the spatter generation with the arc stability. In this paper, to develop the index for estimating the arc stability in short circuit transfer range Of CO2 arc welding, the welding current and are voltage waveforms were measured and the spatter generated was captured and measured. The correlation analysis of the measured amount of the spatter with the factors (the components and the standard deviations of the components) was performed, and the factors that have a considerable influence on the spatter generation among all factors were selected. And some cases of models consisted of the factors were presented, and a mathematical index model which can make an estimation the amount of the spatter from these models with multiple regression analysis. Also, it was compared how much the amount of the spatter generated under the selected welding conditions do these index models fit, and the index model to estimate the arc stability which represent the spatter generation most appropriately was developed

• Journal of Welding and Joining
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• v.16 no.6
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• pp.52-58
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• 1998

The effect of Si content in welding wires on th arc stability was investigate, in the region of short circuit transfer and spray transfer. In the region of short circuit transfer, with increasing Si content, average arcing time and average short circuit time were increased. Therefore, droplet transfer frequency was decreased, due to the increase of arcing time and peak current at the moment of arc-reiginition was increased, due to the increase of short circuit time. In the region of spray transfer, the fluctuations of arc current and arc voltage was the most stable in wire with Si content of about 00.60 wt.%.