Spray mode gas metal arc welding process

Abstract: A spray mode gas metal arc welding process employing a shielding gas mixture comprising (A) 3 to 8 volume percent carbon dioxide, (B) 30 to 40 volume percent argon and (C) the balance helium.

Description: This invention relates generally to spray mode gas metal arc welding with a consumable wire electrode and more particularly to an improved process for gas metal arc welding which can extend the deposition range over which metal can be stably deposited in the axial spray mode. Gas metal arc welding, commonly referred to as "GMAW" or "MIG" welding, is an arc welding process in which the arc is shielded from the ambient atmosphere by a gas. Metal is transferred to a workpeice through the arc from a consumable wire electrode. The consumable wire electrode is continuously fed into the arc at a preselected speed corresponding to a given deposition rate for a given wire size. The mode of metal transfer is dependent upon operating parameters such as, for example, welding current, voltage, wire size, wire speed, electrode extension and the protective gas shielding composition. The known modes of metal transfer include short circuit, globular transfer, axial spray transfer, pulse spray transfer and rotating arc axial spray transfer. Those skilled in the art are familiar with these terms and with their meanings. The short circuit, globular, and pulse spray modes of metal transfer are lower deposition rate processes in which metal is generally deposited at rates below about 4.54 kg/hour (10 pounds per hour (lbs/hr)). The rotating arc axial spray mode of metal transfer is a very high deposition rate process which is unstable at metal deposition rates below about 7.71 kg/hour (17 lbs/hr) using electrode wire size diameters of 0.889mm (0.035 inches) or larger. Below this minimum rate of metal deposition the rotating arc becomes erratic and/or is unsustainable. The axial spray mode of metal transfer is used for depositing metal at rates above the low deposition rates provided by the short circuit, globular transfer or pulse spray modes of metal transfer and below the very high deposition rates obtained in the rotating arc axial spray mode. US-A- 4 749 841 discloses a pulsed arc welding method, apparatus and shielding gas composition. Metal deposition rate is said to be increased with reduced energy input in pulsed arc welding with a consumable electrode and a shielding gas mixture of argon, helium and carbon dioxide, the helium content being in the range from about 16% to about 25% and the carbon dioxide content being from about 1% to 4%. The component gases are stored in separate containers until the welding operation during which precisely metered flows of each are entrained by a metering valve and directed to the weld region. Consistently finished welds are said to be produced, on stainless steel, low alloy steels and nickel based alloys as well as other weldable ferrous metals, including during out of position welding operations. A recent significant advance in the field of gas metal arc welding is the process described and claimed in US-A- 4 645 903, which enables stable deposition in the axial spray mode of metal transfer up to a rate of 11.34 kg/hour (25 lbs/hr) using a wire diameter size within the range of from 0.889 to 1.321 mm (0.035 to 0.052 inch). Prior to the advancement of this patent, the axial spray mode of metal transfer was limited to a metal deposition rate of from 2.27 to 5.44 kg/hour (5 to 12 lbs/hr) using the aforesaid wire sizes. Above the maximum deposition rate, the welding operation becomes erratic and less stable until a rotating arc is established by raising the wire feed rate to the minimum deposition rate required for a stable rotating arc. The non-rotating arc axial spray mode of metal transfer is generally considered to be the preferred choice of metal transfer for all position GMAW welding where reliability, stability, high quality and at least a relatively high deposition rate is required. In the axial spray mode of metal transfer, fine droplets of molten metal are pinched off the end of the moving wire and fed axially through the arc column to the weld pool. The pinch effect is caused by electromagnetic forces on the molten tip of the wire. The rotating spray arc was developed to increase the operating deposition range for GMAW welding. In the rotating arc mode of metal transfer the arc is physically rotated by electromagnetic forces in a helical pattern about a longitudinal axis. As the arc rotates, a controlled stream of metal droplets is transferred from the electrode tip to the weld pool over a relatively wide area. The weld penetration provided by the non-rotating arc axial spray transfer mode is much deeper and is easier to control than that provided by the rotating arc mode. It is thus desirable to have an improved spray mode gas metal arc welding process and it is particularly desirable to have an improved gas metal arc welding process which can extend the deposition range for metal deposition in the axial spray mode. It has now been found possible to provide such improved gas metal arc welding process. According to the present invention there is provided a process for spray mode gas metal arc welding with a consumable wire electrode which comprises (a) forming an arc between the consumable wire electrode and a workpiece; (b) maintaining a substantially constant arc voltage between the wire electrode and the workpiece; (c) feeding the consumable wire electrode through a welding torch contact tube into the arc; (d) transferring metal from the electrode to the workpiece; and (e) shielding the arc with a gas mixture comprising (A) 3 to 8 volume percent carbon dioxide; (B) 30 to 40 volume percent argon; (C) balance helium. Preferably the electrode has a diameter of 0.584 to 1.321 mm (0.023 to 0.052 inch). The electrode is preferably fed at a rate so as to enable the transference of up to 24.95 kg/hour (55 pounds per hour) of metal from the electrode to the workpiece. The arc voltage is preferably from 24 to 51 volts. The arc welding is preferably carried out in the axial spray mode. The contact tube is preferably maintained at a distance from the workpiece to enable an electrode extension of from 12.7 to 38.1 mm (0.5 to 1.5 inches). Preferably the contact tube is recessed in the welding torch which has a torch cup extending beyond the front end of the contact tube, the recess desirably being at least 3.97mm (5/32 inch). The present invention will now be further described with reference to and as illustrated in the accompanying drawings, but in no manner limited thereto. In the accompanying drawings:- Figure 1 is a schematic diagram of one system useful for carrying out the process of the present invention; Figure 2 is a graphical representation of the deposition rate performance of the process of the present invention employing 0.584mm (0.023 inch) diameter wire in the axial spray mode, and of the deposition rate performance of other known methods; Figure 3 is a graphical representation of the deposition rate performance of the process of the present invention employing 0.889mm (0.035 inch) diameter wire in the axial spray mode, and of the deposition rate performance of other known methods; and Figure 4 is a graphical representation of the deposition rate performance of the process of the present invention employing 1.143mm (0.045 inch) diameter wire in the axial spray mode, and of the deposition rate performance of other known methods. Referring to the drawings, in Figure 1 consumable wire electrode 1 is drawn from reel 12 by feed roll 14 through contact tube 16 in gas shielded arc welding torch 2. The consumable wire electrode may have a diameter within the range of from 0.584 to 1.321mm (0.023 to 0.052 inch) and may be composed of any suitable metal composition appropriate for the particular welding application. Examples of suitable metal compositions include any wires such as ER70S-3,-6-7 gas metal arc welding wires called out in American Welding Society Specification A5.18. Any suitable gas shielded torch may be used to carry out the process of this invention. One such suitable torch is the ST-16 torch which is commercially available from L-Tec Corporation. The torch may be either manually operated or mechanized. In the embodiment illustrated in Figure 1, torch 2 is a mechanized torch. Feed roll 14 is driven by drive motor 3 contained in wire feeding unit 18 which can feed wire at the speeds necessary to achieve the desired deposition rates. One commercially available feeding unit is the "High Deposition feeder manufactured by L-Tec Corporation which can feed wire up to about 50 metres per minute (2000 inches per minute (ipm)). To assist in handling the inertia of a rotating wire package it is desirable to employ a coasting braking system with an adaptive burnback circuit to prevent the wire from sticking to the contact tube upon termination of the welding operation. Power supply 20 supplies power to both wire feeding unit 18 and torch 2. Power supply 20 is voltage controlled and of the constant potential type. In operation an arc 4 is established between consumable electrode 1 and workpiece 5 by energizing power supply 20 and feeding the electrode into direct contact with the workpiece. The arc voltage between the electrode and the workpiece is kept substantially constant during the welding process. By "substantially constant" it is meant that the arc voltage varies not more than 5 percent from the setpoint during the welding process. The arc voltage setpoint is at a point where a stable arc is achieved. For example, for 0.584mm (0.023 inch) diameter wire a stable arc is achieved with an arc voltage of between 24 and 30 volts, and for 0.889 to 1.321mm (0.035 to 0.052 inch) diameter wire a stable arc is achieved with an arc voltage between 35 and 51 volts. The consumable wire electrode is fed through welding torch contact tube 16 into the arc and metal is transferred from the electrode to the workpiece. The electrode 1 is fed through the contact tube 16 into the arc 4 formed between the electrode 1 and workpiece 5. Contact tube 16 is connected through torch 2 to power supply 20 for supplying power to electrode 1. Workpiece 5 is connected to ground in common with the power supply ground. Preferably torch 2 is held above or at a distance from the workpiece 5 to ensure an electrode extension or torch to work distance x. For a 0.584mm (0.023 inch) diameter electrode the preferred electrode extension is within the range of from 9.525 to 19.05 mm (3/8 to 3/4 inch), most preferably about 15.875mm (5/8 inch), and for a 0.889 to 1.321mm (0.035 to 0.052 inch) diameter electrode the preferred electrode extension is within the range of from 19.05 to 38.1mm (3/4 to 1-1/2 inches), most preferably about 25.4mm (1 inch). The arc is shielded from the ambient atmosphere by a gas mixture comprising (A) 3 to 8 volume percent carbon dioxide; (B) 30 to 40 volume percent argon; (C) balance helium. Referring back now to Figure 1, the shielding gas mixture useful with the present invention is made up within gas mixer 22 which receives the component gases from cylinders 24, 25 and 26. For example cylinder 24 may contain argon, cylinder 25 may contain carbon dioxide and cylinder 26 may contain helium. Any other suitable gas storage container, such as, for example, a storage tank, may also be employed in conjunction with the present invention. Gas mixer 22 can be any conventional gas mixer which can be set to meter the appropriate gas from each gas source to establish the gas mixture useful with the present invention. The shielding gas mixture useful with the present invention is then passed through conduit means to torch 2 and is passed through space 27 between contact tube 16 and torch cup 28 so that it forms a shroud for shielding arc 4 from the ambient atmosphere. Torch cup 28 preferably extends beyond the front end 17 of contact tube 16 so that the contact tube is recessed within the torch cup for a distancy y. Preferably distance y is at least 3.97mm (5/32 inch). Heretofore the ability to achieve high deposition rates with stability required operation in the rotational spray arc mode. Figures 2, 3 and 4 are graphical representations of the stable deposition ranges for 0.584, 0.889 and 1.143 mm (0.023, 0.035 and 0.045 inch) diameter wire respectively. In Figures 2, 3 and 4 amounts shown in lbs/hr may be converted to kg/hr by multiplying by 0.454, and the amounts in inch/minute may be converted to mm/minute by multiplying by 25.4. Curve A represents the stability region for conventional gas metal arc welding, Curve C represents the stability region for gas metal arc welding in the rotational spray arc mode, and Curve D represents the stability region for the gas metal arc welding process of this invention in the axial spray arc mode. In Figures 3 and 4 additional curve B represents the stability region for the improved gas metal arc welding process disclosed and claimed in US-A- 4 645 903 in the axial spray arc mode. The shielding gas composition used to illustrate the present invention and to generate the data reported in Figures 2 to 4 was comprised of 61 volume percent helium, 35 volume percent argon and 4 volume percent carbon dioxide. Measurements of deposition rate were taken over a wide range of wire feed speeds, for the diameters illustrated, over which stable axial spray was obtained. As can be seen from the graphs of Figures 2, 3 and 4, the gas metal arc welding process of this invention enables, for a 0.584mm (0.023 inch) diameter electrode, a stable deposition rate in the axial spray mode of up to about 6.80 kg/hour (15 lbs/hr) and for a 0.889 mm and 1.143mm (0.035 inch and 0.045 inch) diameter electrode, significantly increased stable deposition rates in the axial spray mode, higher than the other gas metal arc welding methods, even in the rotational spray arc mode. Now by the use of the process and gas mixture of the present invention, one can carry out spray mode gas metal arc welding in an improved manner. In particular one can carry out gas metal arc welding in the preferred axial spray arc mode at a higher stable deposition rate than has been heretofore possible with other known gas metal arc welding methods.

Claims: A process for spray mode gas metal arc welding with a consumable wire electrode which comprises (a) forming an arc between the consumable wire electrode and a workpiece; (b) maintaining a substantially constant arc voltage between the wire electrode and the workpiece; (c) feeding the consumable wire electrode through a welding torch contact tube into the arc; (d) transferring metal from the electrode to the workpiece; and (e) shielding the arc with a gas mixture comprising (A) 3 to 8 volume percent carbon dioxide; (B) 30 to 40 volume percent argon; (C) balance helium. A process according to claim 1, wherein the electrode has a diameter within the range of from 0.584 to 1.321mm (0.023 to 0.052 inch). A process according to claim 1 or 2, wherein the wire electrode is fed at a rate so as to enable the transference of up to 24.95 kg/hour (55 pounds per hour) of metal from the electrode to the workpiece. A process according to any of claims 1 to 3, wherein the arc voltage is within the range of from 24 to 51 volts. A process according to any of claims 1 to 4, wherein the spray mode gas metal arc welding is carried out in the axial spray mode. A process according to any of claims 1 to 5, wherein the contact tube is maintained at a distance from the workpiece to enable an electrode extension of from 12.7 to 38.1 mm (0.5 to 1.5 inches). A process according to any of claims 1 to 6, wherein the contact tube is recessed in the welding torch which has a torch cup extending beyond the front end of the contact tube. A process according to claim 7, wherein the said recess is at least 3.97mm (5/32 inch).

Inventors: CHERNE LAWRENCE WILLIAM, LARSON NILS EDWARD, LETURNO DAVID BRIAN, CHERNE, LAWRENCE WILLIAM, LARSON, NILS EDWARD, LETURNO, DAVID BRIAN
Applicants: PRAXAIR TECHNOLOGY INC, PRAXAIR TECHNOLOGY, INC.
Application year: 1989
Main classification: B23K9
IPC codes: B23K9, B23K35