Techno-economic evaluation on the effects of alternating shielding gases for advanced joining processes

Stuart Campbell, Alexander Galloway, Norman McPherson

Research output: Contribution to journalArticle

13 Citations (Scopus)

Abstract

A new method of supplying shielding gases in an alternating manner has been developed to enhance the efficiency of conventional Gas Metal Arc Welding (GMAW). However, the available literature on this advanced joining process is very sparse and no cost evaluation has been reported to date. In simple terms, the new method involves discretely supplying two different shielding gases to the weld pool at pre-determined frequencies which creates a dynamic action within the liquid pool. In order to assess the potential benefits of this new method from a technical and cost perspective, a comparison has been drawn between the standard shielding gas composition of Ar/20%CO2, which is commonly used in UK and European shipbuilding industries for carbon steels, and a range of four different frequencies alternating between Ar/20%CO2 and helium.
The beneficial effects of supplying the weld shielding gases in an alternating manner were found to provide attractive benefits for the manufacturing community. For example, the present study showed that compared with conventional GMAW, a 17% reduction in total welding cost was achieved in the case of the alternating gas method and savings associated with a reduction in the extent of post weld straightening following plate distortion were also identified. Also, the mechanical properties of the alternating case highlighted some marginal improvements in strength and Charpy impact toughness which were attributed to a more refined weld microstructure.
LanguageEnglish
Pages1863-1872
JournalProceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
Volume225
Issue number10
DOIs
Publication statusPublished - Oct 2011

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Joining
Shielding
Gases
Welds
Economics
Gas metal arc welding
Costs
Straightening
Helium
Shipbuilding
Carbon steel
Fracture toughness
Welding
Mechanical properties
Microstructure
Liquids
Chemical analysis
Industry

Keywords

  • mechanical engineering
  • machinery
  • gases

Cite this

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abstract = "A new method of supplying shielding gases in an alternating manner has been developed to enhance the efficiency of conventional Gas Metal Arc Welding (GMAW). However, the available literature on this advanced joining process is very sparse and no cost evaluation has been reported to date. In simple terms, the new method involves discretely supplying two different shielding gases to the weld pool at pre-determined frequencies which creates a dynamic action within the liquid pool. In order to assess the potential benefits of this new method from a technical and cost perspective, a comparison has been drawn between the standard shielding gas composition of Ar/20{\%}CO2, which is commonly used in UK and European shipbuilding industries for carbon steels, and a range of four different frequencies alternating between Ar/20{\%}CO2 and helium. The beneficial effects of supplying the weld shielding gases in an alternating manner were found to provide attractive benefits for the manufacturing community. For example, the present study showed that compared with conventional GMAW, a 17{\%} reduction in total welding cost was achieved in the case of the alternating gas method and savings associated with a reduction in the extent of post weld straightening following plate distortion were also identified. Also, the mechanical properties of the alternating case highlighted some marginal improvements in strength and Charpy impact toughness which were attributed to a more refined weld microstructure.",
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