Optimization of Hot-wire Fraction for Enhance Quality in GMAW

Abstract The combination of hot-wire insertion technology and gas metal arc welding (GMAW) is proposed to increase deposition rate and reduce power consumption. This study systematically investigated the effect of hot-wire fraction on weld metal properties. The results show that the compensatory deposition rate from hot-wire insertion provides a similar effective height compared with the rate from conventional GMAW, with a lower weld height/width ratio, lower power consumption, and improved mechanical properties. However, an excessive hot-wire fraction can lead to lack of fusion, and this value should be limited to no more than 44% of the total deposition rate. The relative GMAW and hot-wire fractions were optimized to maximize total deposition volume while avoiding lack of fusion and providing sufficient penetration. With the optimized condition, hot-wire GMAW could be efficiently used to obtain similar deposition rates with lower power consumption and without sacrificing toughness properties. This proposed process offers a sustainable alternative development to conventional GMAW.