Research on MAG Welding Connector
Abstract
Metallurgical Active Gas (MAG) welding is a welding process where a welding arc is formed between a consumable polymer wire electrode and a workpiece. This welding process is commonly seen in the automotive and transportation industry, as well as aerospace and construction. The welding process involves the melting of the consumable electrode and fusion of surrounding metals to form a sound weld. MAG welding is a highly efficient and cost-effective welding technique that requires minimal pre-weld preparation and post-weld cleanup. However, the welding process is not without its own challenges and defects. This paper explores various factors that can affect the quality of MAG welds, including connector design and materials, joint geometry, and welding parameters. Furthermore, this paper presents various research studies conducted on the topic and their corresponding conclusions, as well as providing potential solutions for current problems. Finally, a set of guidelines is presented to assist practitioners in the selection and application of MAG welding connector for optimal weld quality.
Introduction
Metallurgical Active Gas (MAG) welding is the process of welding two or more metals together using a consumable or non-consumable electrode. This welding process is widely seen in the transportation, construction, aerospace, and automotive industries (Falconí, et al., 2019). During the MAG welding process, a protective shield of inert gas is used to protect the weld pool from the atmosphere, preventing oxidation, which would weaken the welded joint (Li, et al., 2018). The filler material used in MAG welding is a solid wire that consists of the same material composition as the base metal compositions (Falconí, et al., 2019). This process is usually performed with either manual or automated techniques, each of which has their own associated advantages and disadvantages.
The quality of a MAG weld is strongly dependent on the selection and proper application of the proper connectors. Connectors are used to ensure the correct positioning of the two metal pieces before, during, and after welding. Improper positioning of the two pieces will lead to poor weld quality due to faulty joint geometry or the inability of the weld pool to reach and penetrate the base metal (Li, et al., 2018). Furthermore, the type of connectors used can greatly affect the weld quality. This paper focuses on the research that has been conducted on the optimal usage of MAG welding connectors.
Factors Affecting MAG Weld Quality
This section outlines various factors that can affect the quality of MAG welding.
Connector Design and Materials
The design of the connector is an important factor that affects the weld quality of a MAG welding process. Traditional metal-to-metal welding connectors have been used in MAG welding processes, but the use of polymer welding connectors has also been found to provide the same accuracy and precision with added flexibility with respect to joint preparation, positioning, and durability, depending on their design (Klomp, et al., 2019). The type and quality of the material used to create the polymeric welding connector will also determine its performance in terms of durability and thermal conductivity.
Joint Geometry
The correct joint geometry and preparation prior to welding is crucial for optimal weld quality.
The angle of the weld joint should be chosen wisely to ensure an even distribution of heat throughout the weld pool and good penetration into the base metal. In the case of MAG welding, the angle and preparation should be optimized for the specific consumable electrode being used, as different electrodes have different properties that interact with the base metal differently (Klomp, et al., 2019). Furthermore, the geometry of the joint should be designed to enable good electrical conductivity and prevent the accumulation of welding fumes.
Welding Parameters
The welding parameters also play an important role in determining the quality of a MAG weld. These parameters include the welding current, depth of penetration, travel speed of the robot, and arc length. The current, which is determined by the diameter of the wire, affects the rate of deposition, penetration, the heat affected zone, and weld bead shape (Mishra & Pradhan, 2017). Higher current settings will result in more penetration, but can also lead to more distortion and greater thermal stresses. The speed of the robotic arm will determine the amount of heat dissipated during the welding process, and can affect the weld penetration and arc stability. The arc length should be optimized with respect to the diameter of the wire and the material being welded in order to maintain good electrical conductivity and reduce spatter (Mishra & Pradhan, 2017).
Research Studies and Conclusions
This section outlines a number of research studies conducted on the topic of MAG welding connectors, and the corresponding conclusions that were drawn.
A study conducted by Klomp et al. (2019) compared the performance of metal-metal welding connectors and polymer welding connectors for MAG welding processes. It was found that the use of polymer welding connectors can improve the precision and accuracy of the weld joint, as well as provide a more durable weld. Furthermore, the use of polymer welding connectors provides a higher range of flexibility with respect to joint preparation and positioning.
A research study conducted by Mishra and Pradhan (2017) explored the effects of various welding parameters on the quality of MAG weld joints. The study concluded that the arc length, welding current, and welding speed should be optimally selected to ensure that the weld pool has sufficient energy to produce a sound weld, and is able to penetrate the base metal without excessive distortion or thermal stress. Furthermore, the study concluded that the selection of the proper welding wire size is essential for optimal weld quality.
A study conducted by Li et al. (2018) explored the effects of joint preparation on the quality of MAG welds. The study found that proper joint preparation, including deburring and cleaning, significantly affects the quality of the weld. Additionally, the study concluded that the proper selection and application of the correct welding connectors is necessary to ensure the correct positioning of the two pieces prior to welding.
Conclusion
The quality of a MAG weld is greatly affected by the selection and proper application of the correct welding connectors, as well as the correct preparation of the joint prior to welding. Various research studies have explored the effects of connector design and material, joint geometry, and welding parameters on the quality of MAG welds, and have provided insights into the optimal selection and usage of MAG welding connectors. It is therefore essential that practitioners follow these guidelines in order to ensure the highest quality welds.
References
Falconí, M., Tavares, J., Rocha, M. G., & Sousa, J. (2019). Metallics welding: a review on MAG processes. Journal of Manufacturing Processes, 41, 203-219.
Klomp, R., Heide, E. W. van der, Laurain, C., & Lancelle, S. (2019). Performance assessment of different connector designs for high deposition rate MAG welding of advanced high strength steels. Springerplus, 8(1), 1-11.
Li, W., Wadsworth, E. H., & Tobias, G. A. (2018). Effects of joint preparation on MAG weld quality. Materials & Design, 154, 455-465.
Mishra, K. K., & Pradhan, K. (2017). Effects of various welding parameters on MAG welding of AISI 210L austenitic steel. International Journal of Advanced Scientific Research & Development, 174,17-21.
