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The Effect of Transformer Phasing On Weld Bead Formation in Multi-Electrode Submerged-Arc Welding
The Effect of Transformer Phasing On Weld Bead Formation in Multi-Electrode Submerged-Arc Welding
,1 /y,
r
i
Three-Electrode
Kazuo
Submerged-Arc Welding
Kozo
of Line
Pipe -
<
,
<
by
Agusa1t,
This
undercutting phenomena
point of
arc as
arc
deflection
during
a-c
phasing from the stand powered three-wire submergedphasing sequences are used so
the three
arcs.
,
,
:; j
to
To
evaluate
are
the
arc
1,
y
,
carried
for the
are
electromagnetic
related
to
forces
acting
on
each arc,
j
, _ .
the
undercutting phenomena.
__
---
produce high. quality welds free from undercutting, it is necessary to choose, the phasing sequences which provide the trail arc with the forward deflection predominantly: (1) the lead and the trail currents are in phase, and the phase difference , .
important.
To
,
degs;
j
1
(2)
the
phase difference
degs, and that between the trail and the lead currents is 60 degs; (3) the phase difference between the middle and the trail
is 90
currents
currents
!
,
is 60
degs,
I
,
is also 60
degs;
etc.
arc
Although
determined
the
is
mainly
by
its
electromagnetic
a
ground
of the trail
may inter-
rupt stable
welding operations,
the
use
of the
in-phase sequences
arcs.
Senior Researcher of
Dr.
Welding
Lab.
**
Eng.,
Welding
Lab.
Research
Laboratories,
(1)
1
./
, ,
..ft
.
I
=;
:.
.
)
&dquo;
,
i
1 . ,
i.
j
,
..
y 1
... ..p..
risl,
.
_
,Il j
I.
INTRODUCTION
..,-
-..W
..,.,-......- ,L .v. 1
..&dquo;&dquo; T.-/;
been known
as
one of
the most
impora
;
-
,
I
i
,
,
_
single-wire arc welding system, a increased welding speeds before undercutting occurs. The two-wire three-phase power system connected in V-circuitry provides the trail arc with a longer duration of the forward deflection by
producing
a
)
:
I:
<
speed
wire.
greater than
single
that
of
a
interruption
are
currently
UOE
t
,
being utilized
at
at
our
pipes
&dquo;
speeds beyond
or
the
capabilities of
more
The arc
!
deflections,
phenomena in
however, could
The
complicated becauseof
&dquo;
&dquo;..
purpose
using
of
this investigation
arc
is toreveal the
i
,
relationships
cut
between the
formation the
systems.
To
predict
arc
deflections
were
transformers, electro
magnetic forces
differently.
to
compared
with the
phased propensities
>
phasing sequences.
I
,
II.
EXPERIFENTAL
PROCEDURES
..
investigation
were
made with
a
.
,
I ,
:
.
submerged-arc
welding system.
welds
on
J
,
.
feeders
.
surface of
in
I
&dquo;
,
_
Fig.
1.
,
i
&,dquo;
,
(2)
,
..
.
.. _
I
.
..
i
,
.
&dquo;
,
,
y&dquo;:y.r
,.
j
i
..
&dquo;
The
.
I
use
of
a-c,
,.j,1 ,
prerequia
a.~ y
&dquo;
-.,b,&dquo;.,
,
:I
,
:
>(
11 l;
.r
-l
-S
.
r
I
.
drooping characteristic
power
energized
supply,
with
2000A
,..
&dquo;.
,j
r
;
_
r ,-,
I
:;, .2Y
= x
.:
x
_
[
:
j
,and both of :
,.
z_ :z .
d
_
ay1 .
,
_
, &dquo;&dquo;,
;;
-
were
supplies.
There
are
many
Fig. Fig.
1 1
,
1
tj
I
;
possible
ways to connect
!j
I,
supplies to the primary three-phase power lines, and also to the secondary welding circuitries. In this e):periment, twenty-two particular combinations were chosen to provide the
these power
J
i
welding
currents
with the
phasing sequences
for the
shown in Table 1.
/
,
,
j
i
Experiments.
;
_
-M = L
L - M
-
M isc.
f , T&dquo;
0 90
III
M
<
o.. 90
,
1
&dquo;
L
J :
.
1 2
,
v - , ,
-...;&dquo;
I S
T
j( say
,-=:.
i.. w
L-:=::::
t
8 9
3 3
6 7
,,---=T
_
T ,:0 ,/
T
7 ,ao T L /
L......;
10
jz
j6 16
ILL %g 4 zo
M U
19
20
B6060, T
T
110
w 7L
160; T
L
I,
j
.]
<
13
17
21
-
--.
Tl MI
so
M
,
14
18
22 22
60 I T
Travel
I
,
used is shownin
Fig. 2.
the
Welding
,_L.
!.
were
.
5
,
35
T
,
I
:
supplies:
of-
IT
.
_ j
,
I&dquo;
-<
speed iJas _ ,
ground
starting
. ena of a
,,noticed.
11/
:
j
20 2 5
j
.
.
unless otherwise
/
i
1
(3)
,
,
!
.
Welds
w.t.
x
a
were
deposited
3m
(O.I%C-2.0%Mn;4.8mm dia.)
and
fused-type
(CaO-CaF2-SlO2 system).
&dquo;
;(
I
!
III.
<
arc
deflections is
a-c
high speed
forces
were
alternation of
currents and
Therefore, theoretical
carried
out
-
,
j
calculations of
the three
arcs
electromagnetic
to estimate
for each of
their
deflections.
the
/
!
,
When two
current-carring
in
conductors of semi-infinite
length
on
are
aligned length
parallel,
electromagnetic
force
acting
&dquo;
/
.
the unit
by
the
equation:
F u ialh
where
, /
and
. ........... (1)
/
the currents
ia
and
ib
are
through
the
conductors, 1
... ,
is the
li
p
.
is
j
,
of
.
the
;
.
arc
.
in
<
acting
on
an
arc-is caused
by the
nearest arc
(or
arcs).
2
are
On the
assumption
in
that
Fig.
aligned
on
parallel,
the
electromagnetic
force acting
each electrode ,
/
i
,,
be derived as follows:
.............. (2)
-
/
,
-
;, -
M 4Tijb-%1
f
=.[llm.-m]]
.
.............
.(3) 4
..
..
,
f t= . u imit
,
Imt
_
and
.. .
,
where
ii i-
and
it
are
trail electrodes,
respectively; llm
heading
lmt
are
the electrode
i
!
spacings
defined
respectively;
as
the forces
positive.I (4)
I
,
j
.
. ,
. 1 .
..,
,
. ,
v
,
, .
,.
/
.
,
,
.
,t
Undercutting
rate
-.-.-
, -
..,o
to the
5-^, . _
I.
I
;
U= -2 -X-C, x
where 1 is the
tion and
100
(%)
.
;
.
length
of the bead of
an
undercut
inspec-
If
:
lc
is the
length
are
undercut,
with
both in millimeters.
are
in
the
resulting welds
arcs
are
accompanied
severe
undercutting,
Similar
shown in
one.
&dquo;i
stable
unstable
arcs
and,erratic welds
the trail
wave
,
also resulted
as
Fig. 3b by using
arc
in
phase with
or
the middle
,
&dquo;
Figure 4, thevoltage
suggests that the arc
forms
instability,
arc
the
arc
either the
lead
or
the middle
could be attributed
arcs.
the
excess
I!
As shown
i
,
cutting
rates are
greatly
decreased
by avoiding
the
of the in-
nearest
j
-
results in
.-
with
undercutting.j
,
Appearances
ent
and
cross-sections of welds
are
&:
I.
phasing
..
sequences
shown in
Fig.
5.
.
,I
I
V 50 - 50 - 0 ,
o . 0 J ..
0 - B,/ 50
..
v
50
Lead
A
BspA SP
.
f
--
, i
50- . Middte
,
# ?=
t_
&dquo; j
RP . 1 ,
>
P RP R
.
,
..
.-
[
.
JI
&dquo;
,
&dquo;
._
__.
,
__
...
_
_
,
j
-
/
I
--v. TFoM
50-
.o
. <
Cl T 1 ,. 50 - - /VJ
<
.. ,>
..
) .B
Fig. 4 Voltage Wave Forms for Phasing ivo. 3 Showing ArcInterruptions Caused by Excessive Electromagnetic Forces.
I
!
o
.
(6)
,
,
..
-
&dquo;
,
;
Htminh)nt)nmt)tt)n . T ____________.__.!L―____
No. 12
..
,
j
-&dquo;S
M M
l
;
,
I
_
_ _
,
,
No.18
-
_
.
.
.-<;
.
..
K; *S
.-―t―**!―*
.
<
;
-
J
T
I
,
#
!
:
I,i, B.4
.
SS?
. r ,
No. tU.U 20
j
-
on*)12 ――3-)
126*
t
,
)2d I2CI L,
<
r -
,- ...
-, ― . ,
..
Fig. 5
Appearances and Cross-Sections of Welds Obtained with Three Different Phasing Sequences.
IV-2
Arc Deflections
/.
.
When
discussed from
arc
an
arc
is of
most
shape. The
beregarded
current.
as
the
results of its
electromagnetic
arc
current
Therefore,
the
deflection,
created-by
account.
two
electromagnetic interactions
arc
are
shown in
Fig. 6
in terms of
undercutting
rates.
ground currents,
0tg,
and
(7)
.
.
,
,
,
1
,
<
the trail
are
-- . I middle
mid le
>
.
- ;
,.
{, ,1
,
currents,
1
Omt,
..
.
$o
(l)
ISO 5
c C
a)
Na 13 N&13 s0
so&<)
respectively.
from 0
to
With the
phase
_i_
――
--
:Jt1
,
Ne)8 o
――
attractive force is
dominantly
&dquo;
cu quo; u - &du
<―-1 4
go 90
――
<1,>11 ) (
-
Naa 20
<v> (IV)
tiMI2 0
I
.
two sets of
currents,..while
.h the h within with .h those h range the degrees, tte repulsive force is dominantly
r- c
CL 0
tn 0-0
VI 30-fl -3o 0
0
r-L.
_
j
.
,
<__i
from 90 to 180
3j0
Nais jN<t!5
60
90
120
f22r 150
; It
I .――. Na
?-S3I1
180
j
:1
r
exerted.
ward
arc
deflection
is to be
developed with
Fig.
If.
f
Otg
and
phasingB Xos.
&dquo;
,
-
in
I
,.
(i
j!
2 to 7 where the
are
nearest
two arcs
are
i<
t
I
determined
or
not
by
,
by
the
arc
i
I
I
/
instability, in Fig. 6.
-
the
..
arc
-
interruption,
.
were
not
plotted
i
J ;
In the
to
the trail
arc
is
predominantly
<
,
I
<
subjected
by
I
,
I1
ground currents, undercutting occurs severely. As for the region (II), only one phasing sequence was _ the current ratio of available throughout the
rhe middle and the
..
j
.
.,....,.
,
experimentswith
-
I
,
1-
] B.
>
J....,
not
yield
any
for this
sequence 4
,
-
phasing
,
<
is almost 90
,
degrees,
the
almost
,
comparable.
,
by the ground current Therefore,the resulting backward deflecwhere the deflection of the trail
arc
!
i
,
tion of
the
trail
arc
In the
i
region (III),
:
--
is influenced
by
,
the
two
,
predominant
forces
.
having opposite
be
direci
!
I
ti6ns
et
to
each other,
no
undercutting could
observed.
arc
Yamauchi,
a
al?) reported
with
three-
(8)
i
&dquo;
.,
,&dquo;
t
..
,
j
i
,
i
j
.
, ,
. _ .
;.
.
,
,
.. j
.
,.
,:,
, .,
f.
..
...
&dquo;
,..
-
,
J
/
&dquo;
,
.
wire
,
g
between the middle and the trail currents, and that the
current
arc
ground
the trail
occur
does not
play
an
important role
was
in
determining
i
I
deflection.
If this
with
arc
,
<
the
,
phasing
arc.
(III),
is deflected
predominantly backward by
Kitani,
et
&dquo;
middle
the
al3),
and
Uttrachi,-et
Jil
I
f
that the
phasing
sequences which
belong
to
best welding
performances.
Therefore,
the
in the ;
,:
region (III)
favorable
the backward
arc
by
In
the
region (IV),
the trail
arc
is
subjected
to
the
forward deflection
the
,
by
ground
currents,
reason-
figure,
The
some
of the i
.
:
I
undercutting
welds.
, ,
reason
for thisI
)!
arc
above,
its
might
be determined
by
electromagnetic
interactions not
current.
ground
only Therefore,
by taking
the effect of
forces
electromagnetic
each of the effect of
the ground current into consideration, the acting on each electrode were calculated for
undercutting phenomena.
.
phasing
t
arc
,
_
The forces
acting
on
arcs were
calculated from
no
the The
assumption
Eq. (6)
of
effect of the
ground
current
calculation
on
,
assumption that
acting on 1 the
the trail
performed
of 20mm.
with
....
ground current,
a
ig=il+im+it,
interacts
with ;/
B ,
the trail
,.
current apart
7T
distance,
ltg,
(6)
tg
(9)
,&dquo;
,
;
,
When I
is
negative,
backward deflection
over
predominates&dquo;
so
,
..
forward deflection,
occurs
undercutting
,
&dquo;
range
,
-
as
seen
I is
positive
, .
___B*―cn-=― , in this -_._, in , this - 60 - , 60Qg· D , wO o_ t in Fig. 8. When 4 ay, , . and smaller than 020 j ―――――― ,
B
B
.
..
* 0
,-.
,,-,
.
――――――
. _
...
becomes
comparable
backward
to or
predomiso
4020 0 .-――――
(t*wP_____
I I
>
.
-0
6
.
}
8
,;
nant over
,
deflection,
in this
-4
.
.
-2
0
-
4
-
&dquo;
no
undercutting
occurs
I
,
.,
,
range.
&dquo;,
I
Effect of Deflecting Impulse of Trail Arc upon - nUd ercutt1ng . Undercutting Rate. Rate. .
&dquo;
Fig. 8
-- ,
welds,
to
and
all the
Nos.
arc
of I
correspond
not
the
phasing
to
1, 8, 11, and 15
of
Fig.
7.i
Therefore,
is
an
only
the trail
stability
.
important factor
shapes.
r
IV-4
Effect of Ground Location
,
,
-
1,
...
=_ .
;.
_
B
<
ground
out
current
upon weld
I
,
quality,
ground
further experiments
were
carried
by changing
theS
-
location...,
Figure
9 represents the
I
-
relationships
between the
ground ;]
which fall
As for the
undercutting rate for the phasing Nos. 9 and 17 in the regions (III) and (I) of Fig. 6, respectively. phasing No. 17, the ground connection made at the startthe trail
arc
I,
&dquo;.
predominantly and affected the weld bead formationadversely, as previously shown in Fig. 7e. The ground connection made at the finishing end,
ing
however, improves the weld quality
as
end
provided
1
&dquo; j
.1
i
I
*
i
.
phasing No. 9,
the trail
arc
with the
ground
starting end,.
The
deflected
as
only slightly
and aided in
maintaining stable
previously
shown in
Fig. 7c.
ground
deteriorates the
&dquo;
of welds
as
shown in Fig. 9.
ground
current
little
formation.
(13)
/
>
i
i
,
.
―,- -*
/ ,&dquo;
0
/ ,> , . , . - . , I
,
,,
<
L! J.
&dquo;
&dquo;
..
&dquo;,.u .
&dquo;
>
j
,
_
,
[
.i
:;
.
&dquo;
>
j
2
<
&dquo;
.<
.,
i
j
&dquo;
li 20 / 4 .r&dquo;&dquo;&dquo;
1r 0,
.. .
<
4
.
_ .. _
220
300 - i
380
-TrQvel ( cm/min )
Relationships between Undercutting Rate for Phasing
V.
&dquo;
;
j
,
Fig. 9
.-
CONCLUSIONS
The
on
following
conclusions
are
phasing
sequences and
undercutting phenomena
;,
.... ._ , ,
free from
undercutting,
it is
necessary
arc
the
the
provide the trail with the forward deflection predominantly: (i) the lead and trail currents are in phase, and the phase difference between middle and the other currents is from 60 to 180 degs; (ii) the
to
.
_
,
,
!
_
phase difference
degs, and that between the trail and the lead (iii) the,phase difference between the middle is 60 degs, and that between the lead and the
also 60
is 60 degs;
.
_
currents:i
,,
middle currents is
.
·F
&dquo;<
degs;
etc.
>
, ,
,
trail
arc
is
mainly determined
i
,
ground
,
trail
arc.
,
(3) Since
interrupt stable
should be
welding operations,
the
use
of the
arcs.
in-phase sequences
two
/
(14)
!
,!
I
*
f
&dquo;
1
r
.,
I
1) 2)
3)
Doc.
I
:
I
I
REFERENCES RE1;ERENCES
Arc
Welding
Physics,
(1970)
JIW commission of
~
-:
4);ttrachi,
No.6,
Welding Process, Doc. SW-139-68 (1968) G.D., and Messina, J.E., Welding Journal, Vol.47, ,/
pp. 475-481
:
.
(1968)
!
i
:
I
.
:,5 ,I
f
1
I
I
.
,1
&dquo;
BI
I
.
*A-
(
-
Ifp, I!
I.
F
! /
I
.
I
I
I
/
i
/
I
t. !
(15)
J,
,
>
a
&dquo;
c
/
IIW
,
.
XII-A-/6,-79 XII-A-/t-79
,
I
.
-5
.
I
,
1
-
-I
Line-Pipe
/
j
Three-Electrode
Submerged-Arc Welding
of
!
I
I
_
>
t
)
i
by
Kazuo Agusa .
Kozo Akahide
Junichiro Tsuboi
-/1
1
)
i
January 1979
Research Laboratories
KAWASAKI STEEL CORPORATION