Selection of parameters of pulsed current gas metal arc welding

Pulsed welding is a controlled method of spray transfer, in which the arc current is maintained at a value high enough to permit spray transfer and for long enough to initiate detachment of a molten droplet. Once the droplet is transferred the current is reduced to a relatively low value to maintain the arc. These periods of low current allow the average arc current to be reduced into the range suitable for positional welding, while periodic injection of high current pulses allows metal to be transferred in the spray mode. Parameters of these current pulses, such as IpIb, Tp and Tb have a distinct effect on the characteristics viz., the stability of the arc, weld quality, bead appearance and weld bead geometry. Improper selection of these pulse parameters may cause weld defects including irregular bead surface, lack of fusion, undercuts, burn-backs and stubbing-in. Therefore, it is important to select a proper combination of parameters of the pulsed current for welding, which will ensure that the process gives proper results in all the above aspects. However, arriving at such a combination of parameters without a rational base would be only a matter of chance with a fairly low probability for achieving desirable weld properties, since the complexity and interdependence of pulse parameters involved in this process. These difficulties of setting-up the welding conditions correctly has been one of the main reasons for the lack of popularity of pulsed GMA welding in industries. Hence, a detailed study is essential to arrive at a method of predicting the conditions that will give a good weld and this paper reviews various aspects of the pulsed GMA welding, the effects of pulse parameters and different methodologies adopted for selecting these parameters to obtain better quality welds.