Comparison of arc stability and variability of geometry of welds obtained by MIG/MAG and FCAW processes

Despite their similarity, the MIG/MAG and Tubular Electrode processes display particular features with regard to arc stability and variability in the characteristics of the beads. Thus, selection of one of these processes for a specific application will have to consider how these particular features affect the quality of the welds. To support this choice, the present study aimed to investigate how changing the average current affects the stability and regularity of metal transfer in welds carried out with constant voltage and pulsed current and compare the variability in the geometry and dilution of these welds. To achieve these aims, automatic welding was carried out, with steel ABNT 1020 as base metal and wire AWS ER70S-6 and AWS E71T-1 as filler metals. Besides the welds with variation in the average current, the tests involved determination of the parameters for occurrence of stable short circuiting, drop and pulsed transfer. The results showed that the voltage that gives the highest stability in short circuiting transfer is independent of the welding speed and increases with the wire speed, and also showed that welds made with hollow wire displayed greater variability compared to solid wire.