Accepted Manuscript

Cold metal transfer (CMT) technology - An overview

S. Selvi, A. Vishvaksenan, E. Rajasekar

PII: S2214-9147(17)30102-2
DOI: 10.1016/j.dt.2017.08.002
Reference: DT 266

To appear in: Defence Technology

Received Date: 16 May 2017

Revised Date: 26 July 2017
Accepted Date: 18 August 2017

Please cite this article as: Selvi S, Vishvaksenan A, Rajasekar E, Cold metal transfer (CMT) technology -
An overview, Defence Technology (2017), doi: 10.1016/j.dt.2017.08.002.

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 ACCEPTED MANUSCRIPT

Cold Metal Transfer (CMT) Technology - An Overview

Other Author Details:

A.Vishvaksenan , Mechanical Engineering, Institute of Road and Transport Technology, Erode – 638 316,

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Tamilnadu, India.

Dr. E. Rajasekar, , Associate Professor,Automobile Engineering

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Institute of Road and Transport Technology, Erode – 638 316, Tamilnadu, India.

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Cold Metal Transfer (CMT) Technology - An Overview

Abstract

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Cold Metal Transfer technology has revolutionized the welding of dissimilar metals and thicker
materials by producing improved weld bead aesthetics with controlled metal deposition and low heat-
input. In this study, the process, weld combinations, laser-CMT hybrid welding and applications of

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CMT welding are critically reviewed. Microstructure and other weld characteristics have been
discussed at length for various base metal combinations. Particularly, the welding of aluminium and
steel with better results has been possible with CMT Welding. The results reviewed in this article

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indicate that the CMT-Laser hybrid welding is more preferable to Laser or Laser hybrid welding.
CMT welding has found applications in automobile industries, defence sectors and power plants as a
method of additive manufacturing.

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Keywords: Cold Metal Transfer [CMT]welding, Laser-CMT welding, Additive manufacturing,
Composite Joint, Metal Inert Gas[MIG], Metal Active Gas[MAG].
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1. Introduction
Cold Metal Transfer welding is a modified MIG welding process based on short-circuiting transfer
process developed by Fronius of Austria in 2004. This process differs from MIG/MAG welding
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process only by the type of mechanical droplet cutting method not previously encountered [1]. During
welding, temperature variations in welds and parent metals have important effects on material
characteristics, residual stresses as well as on dimensional and shape accuracy of welded products [2].
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Cold Metal Transfer provides controlled method of material deposition and low thermal input by
incorporating an innovative wire feed system coupled with high-speed digital control [3]. The wire
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feed rate and the cycle arcing phase are controlled to realise sufficient energy to melt both the base
material and a globule of filler wire [4]. There are two main features of the CMT process: one is at the
point of short circuit with low current corresponding to a low heat input, another is the short circuit
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occurrence in a stable controlled manner.

Kah et al. introduced the short-circuiting transfer process named “mechanically assisted droplet
deposition” which is applied in controlling short circuit by retracting the wire from short-circuiting
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[5]. Schierl reported that the droplet detachment mode of CMT process is without the aid of the
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electromagnetic force compared to the conventional MIG process, so the spatter can decrease [6].
Pickin and Young previously reported the basic operating principles of the process [3]. Feng et al.
pointed that the CMT process is especially suitable for welding thin aluminium alloy sheets due to the
low heat input and the slight deformation [7]. Additional studies by Zhang et al. and Cao et al.
concentrated on the application of the process in dissimilar alloys joining owing to the low heat input,
which restrains the formation of brittle intermetallic compounds [8, 9].

A graphical interface was developed by Sónia Meco et al using interpolation and neural network
method to help the user select the appropriate CMT welding parameters for the desired application, by
a graphical visualization of the welding profiles, which leads to time, material and cost saving [10].
Amin S. Azar produced a heat source model to simulate the effect of periodic and recurrent arcing and
metal deposition phenomena in the cold metal transfer type of welding. This model will facilitate
studying of weld pool behavior and resultant mechanical properties [11]. Neutron imaging and
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Quantitative infrared analysis are some of the recent non-destructive tests performed on the CMT
weld specimen [12,13]. A required model for simulating the characteristic cooperation between wire
feeding and heat input was published by Fengyuan Shu et al [14].

2. Cold Metal Transfer process

In the CMT process, when the electrode wire tip makes contact with the molten pool, the servomotor
of the ‘robacter drive’ welding torch is reversed by digital process control. This causes the wire to
retract promoting droplet transfer which is depicted in Fig.1. During metal transfer, the current drops
to near-zero and thereby any spatter generation is avoided. As soon as the metal transfer is completed,

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the arc is re-ignited and the wire is fed forward once more with set welding current reflowing [1].

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Fig.1 High-speed images of droplet transfer
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A typical CMT welding electrical signal cycle can be defined as the period required to deposit a
droplet of molten electrode into the weld pool. The analysis of current and voltage waveform is
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essential to study the energy distribution of different phases in droplet transfer process [15]. The cycle
is divided into three phases as follows:
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(i) The peak current phase: This is a constant arc voltage corresponding to a high pulse of current
causing the ignition of the welding arc easily and then heats the wire electrode to form droplet.

(ii) The background current phase: The phase corresponds to a lower current. The current is
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decreased to prevent the globular transfer of the little liquid droplet formed on the wire tip. This phase
continues until short circuiting occurs.
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(iii) The short-circuiting phase: In this phase, the arc voltage is brought to zero. At the same time,
the return signal is provided to the wire feeder which gives the wire a back-drawing force. This phase
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assists in the liquid fracture and transfer of material into the welding pool [7].

Fig.2 Current and Voltage waveforms of CMT process

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The complex waveform of the welding current in the CMT process and the ‘back feeding’ of the filler
wire that mechanically forces the metal transfer make it difficult to understand the relation between
welding parameters, metal transfer and heat transfer as shown in Fig.2, which is studied by Mezrag et
al. for Al 4043-S235 weld joint [16]. With perfect arc length management and high edge coupling
tolerances, the CMT process is sure to be involved in various industrial applications in future as a
solution to overcome the drawbacks of current welding practices [17].

3. CMT welding of similar metals

CMT has accomplished the efficient welding of many similar aluminium alloys. The similar metal

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welds prepared using CMT for variety of alloys are discussed below.

3.1 Inconel 718 alloy

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The microstructural analysis has demonstrated no lack of fusion proving the weld quality as good.
The Heat Affected Zone (HAZ) presented in Fig.3, is small in size (0.5 mm) when compared to the

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same produced by classical MIG welding. The size and geometry of crystallites in the weld zone, i.e.
large dendrites, are similar to those obtained in classic MIG process. After performing EDS chemical
analysis, no significant variation has been detected in the homogeneity of the weld bead. The residual
stresses are found to be minimum. This work by Benoit et al demonstrates that the CMT welding is

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fully suitable for the welding of Inconel 718 [18].
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Fig. 3 Weld zone of Inconel 718 alloy Fig. 4 Weld zone of Al 7075 alloy

3.2 Aluminium 7075 alloy

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The joints were prepared without spatter, cracks and having very low porosity. The joints exhibited
minimum micro-hardness in the Weld Zone (WZ) depicted in Fig.4, and slight hardness decrease in
HAZ compared to the Base Metal (BM).The comparison of microhardness between WZ and HAZ
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could be observed in Fig.5. The joint had mechanical property coefficients of 77%, 60% and 69% for
yield strength, ultimate tensile strength and elongation respectively. The CMT welding performed by
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Elrefaey was found to produce joints with mechanical characteristics better than the conventional
MIG and TIG processes and comparable to FSW and LBW processes [19].

Fig.5 Microhardness profile at WZ/HAZ interface

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3.3 Aluminium AA6061 alloy
When Pavan kumar et al., welded thin aluminium alloy sheets using filler, which is of same
composition as of base metal, the weld exhibited a quasi-binary composition. This composition is
potentially less susceptible to solidification cracking, controlled fusion line, narrower heat affected
zone (HAZ) and reduced intermetallic phase area. The microstructures for different weld parameters
seen in Fig.6 revealed fine recrystallization at the joints. A uniform distribution of grains and its size
in weld HAZ and base metal was distinctly visible [20].

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Fig. 6 Microstructures of AA6061 alloy as seen from Optical Microscopy

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3.4 Galvanized sheet steel
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Joints of galvanized steel, made with electrode wire CuSi3 were subjected to microscopic
metallographic examination displayed in Fig.7, which included both the weld zone and the base
material. Macro- and microscopic metallographic examination by Magda et al confirmed the high
quality of the brazed joints, showing both the existence of a copper diffusion area and the undamaged
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zinc layer in areas adjacent to the weld [21].

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Fig.7 Brazed weld zone Fig.8 Porosity formation mechanisms at different heat inputs
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3.5 Galvannealed steel

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Low and high heat input conditions had a tendency to less porosity formation in weld bead, whereas
the medium heat input conditions were the most susceptible to porosity formation. Solidification
started early in low heat input conditions, resulting in small porosities near the weld root which are
avoided in high heat input conditions [22]. Fig.8 depicts the different porosity formation mechanisms.
Ahsan et al. developed optimized welding conditions to reduce porosity for two heat range inputs, one
at low heat input ranging from 200 to 250 J/mm and the other at high heat inputs, starting from 350
J/mm and rising up to 550 J/mm [23].

3.6 Aluminium 5083-H116 alloy

Jair Carlos Dutra et al. used two different wire electrodes Al 5183 and Al 5087. Weld using Al 5087
electrode showed better mechanical performance in tensile tests. The micro-hardness was similar in
both the WZ and HAZ. Practically, both wire-electrodes showed the same toughness. Crack Tip
Opening Displacement Toughness test results indicate that the applied combinations of base and feed
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material yield good cracking resistance characteristics. Fig.9 displays SEM images, which illustrate
higher incidence of pores with the Al 5183 wire electrode [24].

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Fig.9 SEM micrographs of fractures in weld joints using 5087 and 5183 filler wires

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3.7 Aluminium AA7A52 alloy

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Feng et al. found that the intergranular segregation, which gave birth to the coarse grain boundary
between the weld passes as depicted in Fig.10, were indicated to exhibit inferior mechanical
performances. Tri-axial stress distribution in the fusion zone was indicative of tendency to tensile
failure under service conditions [25]. The softened zone was much wider inside the base plates than

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close to the flat surfaces. The strip-shaped quenched zone was obviously narrower than the averaging
zone internal plates [26].
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Fig.10 Microstructure of molten zone Fig.11 Weld microstructure in longitudinal direction

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3.8 AA2219-T851 alloy

A narrow finger-shaped geometry was observed by Cong Baoqiang et al. using the conventional CMT
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process. There are a large number of gas pores in the lower and upper parts of welds. Fig.11 shows
the weld microstructure in longitudinal direction using conventional CMT welding. The porosity was
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reduced effectively with the help of CMT welding [27].

4. CMT welding of dissimilar metals

CMT welding is also widely employed for welding of dissimilar metals such as aluminium and steel.
The novel dissimilar welds prepared using CMT are discussed below.

4.1 Zinc coated steel (Q235) and wrought aluminium (6061)

The intermetallic layers formed at the interface between zinc coated steel and wrought aluminium are
predominantly FeAl3 phase. Zhang et al. found that CMT increases the strength of the dissimilar metal
lap joint by decreasing the thickness of the brittle intermetallic compound at the interface between
aluminium and steel. The tooth like structure as displayed in Fig.12, predominantly formed during
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solidification is mainly controlled by the diffusion of Fe and Al atoms at the interface between molten
aluminium and solid steel [28].

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Fig.12 Interface between weld metal and steel Fig.13 Microstructure of brazing interface

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The CMT welding of Q235 with Al6061-T6 by Cao et al produced strength equal to CMT welding of
Al6061-T6 with Al6061-T6. The joint strength was found to depend on the thickness of the
intermetallic layer shown in Fig.13, and softening of the Aluminium heat affected zone [9].

4.2 Magnesium AZ31 and Aluminium 1060 alloy

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Wang et al. observed no weld defects as low heat input and addition of Si to the weld effectively
inhibit the creation of brittle intermetallic compounds, which is checked using X-ray diffraction.
Fig.14 is the fusion zone near the Mg substrate, which dictates the strength of the joint and its
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microstructure. Four continuous layers consisting of solid solution layer, eutectic structure layer,
Mg17Al12 layer and Mg2Al3 layer are observed. The micro-hardness in the fusion zone near Mg side is
about 230–240 HM higher than the weld metal 120 HM and the Mg substrate 60 HM [29].
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Fig.14 Micrograph of fusion zone Fig.15 Fracture morphology

4.3 Magnesium AZ31 Band and 6061 Al alloy

When Jing Shang et al. used pure Cu as filler metal, the intermetallic compounds AlCu, CuAl2,
Cu9Al4 were present in the fusion zone of Al side, and Cu based solid solution was generated in weld
zone, while Cu2Mg and Al–Cu–Mg ternary eutectic structure was formed in the fusion zone of Mg
side. The bonding strength of the joint was 34.7 MPa. Fig.15 presents the fracture morphology. The
fracture occurred at the fusion zone of Mg side where the value of micro-hardness was the highest due
to large amount of Cu2Mg intermetallic compound [30].

With ER4043 as filler metal, the CMT weld of AZ31B magnesium and 6061 aluminium alloy
developed by Shang Jing et al. had uniform micro-hardness in both the sides of the substrate, about
540 MPa in Mg side and 350 MPa in Al side as seen in Fig.16. The highest value of micro-hardness
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was 2380 MPa in the fusion zone of Mg side. The micro-hardness in the weld from Mg side to Al side
showed a decreasing trend with reduction of intermetallic compounds. The joint with low bonding
strength was brittle fractured in the intermetallic compound layer of the fusion zone of Mg side.
Intermetallic compounds of Mg2Si, Mg2Al3 and Mg17Al12 distributed continuously in the fusion zone
presented in Fig.17, are responsible for the fracture [31].

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Fig.16 Distribution of microhardness of the joint

In the presence of Al-5%Si as filler metal, maximum tensile strength of 360 N/mm was achieved by

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Madhavan et al. Increase in tensile strength was attributed to minima tensile stress and finer
precipitates. Improved pitting corrosion resistance was observed due to the formation of Mg2Si and
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Al6Mn in the interfacial layer. The micrograph of the entire weld section can be observed in Fig.18
[32].
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Fig.17 Fusion Zone Fig.18 Weld cross-section Fig.19 Weld interface

Magnesium AZ31B and Al 6061 alloy was welded with Variable Polarity CMT welding (VPCMT)
by Peng Wang et al. The Mg–Al IMC layers were formed in the weld interface, near the AZ31B side
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of the welded joints and consisted of three intermediate layers: Mg2Al3 layer, Mg17Al12 layer, and
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Mg17Al12+α-Mg solid solution eutectic layer (very thin) as shown in Fig.19. With decreasing EP/EN
ratio from 4:1 to 1:4, the thickness of the whole IMCs layer was gradually increasing and the tensile
strength increased significantly. All samples were fractured in the hard brittle IMCs layer [33].

Fig.20 Magnified view of weld cross section and corresponding schematic phase distribution
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Welding of Mg AZ31B and Al 6061-T6 sheets yielded significant amount of Mg rich intermetallic
compounds displayed in Fig.20, which degraded the weld strength at the side of Mg alloy base metal.
Both Madhavan et al and Cao et al obtained similar results for the above weld [34,35].

4.4 Hot dip galvanized steel and aluminium 1060 alloy

Zhang et al. noted that the compound layer at the interface between steel and weld metal mainly
consisted of Fe2Al5 and FeAl3 phase. Fig.21 shows a SEM image of Steel-Weld metal interface. The
thickness of the intermetallic compound layer was controlled under 5 micrometre guaranteeing the
joint strength. The tensile strength arrived at was 83MPa [8].

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Fig.21 Steel-Weld metal interface Fig.22 Steel aluminium interface
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4.5 Aluminium (AA6061) and low carbon steel alloy

Higher shear strength and fusion line failure were recorded by Jian Lin et al. when zinc coating was
provided to the steel sheet. Otherwise, it led to lower shear strength and interface failure. The
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maximum principle stress and deformation energy were proposed as the criteria for the interface
failure and plastic strain was proposed as a criterion for the fusion line failure. Fig.22 displays the
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interface between steel and aluminium [36].

4.6 Magnesium AZ31 and Hot dipped galvanized mild steel

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Cao et al. reported that the zinc coating on the surface of the steel is essential for a sound weld. Fig.23
shows the brazing interface, which consists of Al, Zn, Mg intermetallic compounds and oxides (i.e.,
MgFeAlO4, Fe2O3, and Mg2Zn11) and a magnesium solid solution. Aluminium in the welding wire
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magnesium AZ61 enhances the wettability of an Mg-rich weld metal on Zn-coated steel sheet [37].
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Fig.23 Weld metal near brazing Fig.24 Brazing interface between Fig.25 AA6061-T6/Steel
interface fusion joint and Ti alloy matrix fusion zone

4.7 Aluminium A6061-T6 and titanium Ti–6Al–4V alloys

The IMCs at the brazing interface shown in Fig.24 mainly composed of two layers: the continuous
layer which consisted of Ti3Al and TiAl close to the solid Ti alloy, and the discontinuous serration
shaped TiAl3 layer next to the weld metal. Cao et al. observed fractures at the welding/brazing
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interface and weld metal, and at the Al HAZ with most joints fractured in the latter mode. The tensile
strength of the joint is high up to 194 N/mm [38].

4.8 Aluminium AA6061-T6 to galvanized steel alloy

It was found by Cao et al. that a sound joint could be obtained if the wire feeder speed is properly
controlled. The brazing interface between the Al weld metal and galvanized mild steel was found to
consist of about 5–8 micrometre thick FeAl3 intermetallic. The microstructure of the fusion zone is
displayed in Fig.25. In addition, the material stacking sequence affected the strength of CMT spot
plug welded joints. The strength of spot plug welded AA6061 joints was found to be lower than that

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of Al AA6061-to-galvanized mild steel joint [39].

4.9 Magnesium alloy AZ31B and pure copper T2 alloy

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The weld toe-brazing zone and weld root-brazing zone depicted in Fig.26(a) and Fig.26(c)
respectively were similar and consisted of only one IMC (Mg17Al12 + Al6Cu4Mg5 + α-Mg) layer.

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However, the intermediate brazing zone observed in Fig.26b consisted of two IMC (Mg2Cu + MgCu2
+ Al6Cu4Mg5 and Mg17Al12 + Al6Cu4Mg5 + α-Mg) layers. When the thickness of the brazing interface
layers between the Mg weld metal and the Cu base were in the range of 80 to 350 mm, the lapped
joint can reach higher strength of 172.5 N/mm. It was concluded by Cao et al that, in this range the

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thickness of intermetallic brazing interface layers has no obvious effect on the tensile shear strength of
the lapped joint [40].
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Fig.26 Microstructure of a) Toe-brazing zone b) Root-brazing zone and c) Intermediate zone

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4.10 Pure titanium TA2 to magnesium alloy AZ31B alloy

For Mg–Ti joint, satisfied weld appearance and higher tensile load of 2.10 kN was obtained. For Ti–
Mg joint, a tensile load of 1.83 kN was detected. The brazing interface developed by Cao et al. was
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mainly composed of Ti3Al, Mg17Al12 and Mg0.97Zn0.03 intermetallic. Elements Al and Zn in the Mg
base metal and Mg wire are crucial to join successfully Mg and Ti base metals [41]. The weld
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interface of Mg/Ti joint and Ti/Mg joint are displayed in Fig.27 and 28 respectively.

Fig.27 Weld interface of Mg/Ti joint Fig.28 Weld interface of Ti/Mg joint
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4.11 5083-H111 and 6082-T651 aluminium alloys

The micro-hardness of the welded joints was similar to characteristic hardness traverse across
weldments, hardness drops were slightly close to the base metal. The weld joints and base metal had
adequate tensile strength values. Fig.29 shows the Macrograph and SEM photos of the fracture
surfaces of the Fatigue specimen. It was noted by Beytullah Gungor et al. that the CMT welding
results were closer to FSW, and had higher yield strength values than any other welding methods [42].

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Fig.29 Fracture surface of fatigue Fig.30 Microstructure of a) Ti-weld interface and
specimens b) Cu-Weld interface

4.12 Titanium TA2 to pure Copper T2 alloy

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Cao et al. obtained satisfactory lap welded joints with desired welding appearance and good
wettability and spreadability of filler metal on the surface of both alloys. A layer of IMCs, i.e. Ti2Cu,
TiCu and AlCu2Ti were present in titanium-weld interface. The microstructures of Ti-weld interface
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and Cu-weld interface are depicted in Fig.30. The tensile shear strength of the Joint I (top Cu sheet–
bottom Ti sheet) reached 197.5 N/mm while the tensile shear strength of the Joint II (top Ti sheet–
bottom Cu sheet) can reach 205.8 N/mm. The Joint II and I had a comparable strength to CMT lap
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welded Cu-T2 to Cu-T2 with a tensile strength of 194 N/mm. The joints all fractured in the Cu HAZ
with plastic fracture mode [43].
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In CMT welding–brazing butt joint of Titanium TA2 to pure Copper T2 alloy by Cao et al., the
thickness of the IMCs layer was not uniformed: 117–129 µm in middle groove surface and 80–100
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µm in root groove surface, are presented in Fig.31 and Fig.32 respectively. The IMCs layers at the
brazing interface mainly consisted of Ti2Cu, TiCu and AlCu2Ti respectively from the Ti base metal to
the weld metal. Tensile loads of 5.10 kN were reached, and fracture occurred at Cu HAZ [44].
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Fig.31 Middle surface of brazing interface Fig.32 Root surface of brazing interface
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4.13 Hot-dip galvanized steel sheet and Aluminium 5052 alloy

Minjung Kang and Cheolhee Kim concluded that the Si composition of the filler metal primarily
influence the thickness of the IMC layer. Using AlSi (Al 4043 and Al 4047) filler wire, the growth of
the trapezoidal Fe2Al5 layer into the steel base materials was restricted, and a nearly flat interface
between the IMC layer and steel was observed. The specimens were fractured at the HAZ of the Al
5052 alloy. Fig.33 shows the IMC thickness variation from the root [45].

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Fig.33 Variation of thickness according to the IMC

4.14 Aluminium 5A06 with pure Ni N6 plates

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The weld joint prepared by Liu et al can be divided into four parts: the nickel base metal; Ni3Al,
Ni0.9Al1.1 and Ni2Al3 IMC layer; columnar NiAl3 layer; and Al–Si solid solution weld, as formed
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sequentially from the nickel side to the aluminium side. With an increase in welding velocity, the
thickness of the IMC layer first decreased and then grew. This is depicted in Fig.34. The greatest
shear strength obtained was 42MPa. The joint strength continued to decrease as the IMC layer
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thickened. The fractures were mainly located in the NiAl and NiAl3 IMC layer [46].
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Fig.34 Effect of welding velocity on microstructure of Al–Ni joint a) 9mm/s, b)11mm/s,

c) 15mm/s, d)7mm/s.
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4.15 5182-O and 6082-T4 Aluminium alloy sheets
In the 5182 sheets, the HAZ microstructure showed fine precipitates of second phase and coarsening
of the Mg2Al3 precipitates in the aluminium matrix. In general, it was found by Ahmed Elrefaey and
Nigel G. Ross that CMT welding of 5182 to 6082 alloy did not show worse mechanical properties
compared to 5182/5182 and 6082/6082 joints. Fig.35 displays the weld zone images of 5182/6082
weld [47].

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Fig.35 WM/6082 HAZ and WM/5182HAZ Fig.36 Steel/Cu and Cu/Ti weld interface
4.16 Titanium AMS4911L with 316L stainless steel

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Gonçalo Pardal et al. obtained maximum tensile properties at higher heat input. The IMCs formed are
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more ductile in nature when compared to the Fe-Ti IMCs and were mainly located at the interfaces
between the parent metals and the Cu (filler wire). The maximum hardness measured was 1000
HV0.1. The weld interfaces are presented in Fig.36 [48].
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4.17 A6061-T6 aluminium alloy to Dual Phase 800 steel

The grains in nugget zone near HAZ coarsened and the Mg2Si phase dissolved, which resulted in Al
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softening and as a result, the joint strength was reduced. Madhavan et al discovered the presence of
the Fe3Al and Fe2Al5 phases in the weld nugget from the XRD and electron microscopy analysis.
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Thickness of the IM layer seen in Fig. 37 varied from 1.49 to 3 mm for the P-CMT and CMT
processes respectively. At the interface, fi-FeAl3 and g-Fe2Al5 phases were formed. The CMT and P-
CMT welds failed at the Al HAZ. This failure mode has ductile fracture characteristics with dimples
and voids [49].
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Fig.37 a) SEM b) TEM image of IM layer Fig.38 Al/STO6 Z steel weld joint

4.18 AC 170 PX aluminium alloy and ST06 Z galvanized steel sheets

The thickness of interfacial layer was only 0.6 µm. The tensile shear strength reached 189 MPa which
is 89% of the aluminium alloy base metal. The spalled needle-like IMCs visible in Fig.38 were
confirmed as Al-Fe-Si ternary intermetallic compounds by Song Niu et al., which had negative effect
on tensile strength of the joint. With increasing welding current, the needle-like IMCs grew longer
and spread further into the weld, reducing the tensile shear strength of the joint [50].
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4.19 304 stainless steel and 5A06 aluminium alloy sheet

Under the effect of an axial EMF, both the welding arc and the molten drop were rotated by Lorenz
force. The EMF influenced the growth of the Al/Fe IMC layers during Al/steel welding. Under EMF
application, the diffusion of Fe to the weld was suppressed and the Si content in the IMC layers
increased, which restrained the growth of brittle Al/Fe IMC phases. Fig.39 contrasts the difference
observed while applying an axial EMF during CMT process. Yibo Liu et al. found that the application
of the EMF increased the tensile shear force of the weld joint. At EMF frequencies of 0 Hz and 5 Hz,
stronger joints were obtained, and within crease in coil current, the joint strength increased even

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further [51].

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Fig.39 Microstructure of the Al/steel lap joint interface (a) without EMF (b) with EMF
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5. Comparison of CMT and Metal Inert Gas Welding
The tests conducted by Mateusz Grzybicki and Jerzy Jakubowski shows that compared to traditional
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MIG variety welding, the CMT method has several advantages such as low energy, spatter free, high
welding speed. It also enables the welding of thin sheet metals. However, there is a great danger of
incomplete fusion, especially for lap joints which could be avoided by increasing the arc length [52].
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The CMT welding by Jair Carlos Dutra et al. showed more stability and the root produced showed a
good finish, both on the surface and back of the joint than the conventional MIG welding [53].
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6. Laser-CMT arc hybrid welding of metals

6.1 Laser-CMT arc hybrid welding of T2 copper
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Yulong Chen et al. achieved continuous and regular welds at a minimum power of 2 kW, which is
very much less than the minimum power level of laser welding (about 5kW). A large amount of Si-
rich precipitates were found in the Fusion Zone (FZ) grains of the hybrid welds, which caused the FZ
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of hybrid welds to be harder than laser welds. Fig.40 shows the Si-rich precipitates in the FZ of the
hybrid welds. The UTS, YS, and the Elongation of the hybrid weld with the best performance were up
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to 227 MPa, 201 MPa, and 21.5 %, respectively. The decrease of the porosity was the main reason for
strengthening of hybrid weld [54].

Fig.40 Precipitates in FZ of Fig.41 Microhardness distribution Fig.42 Equiaxed dendrites in the

hybrid weld centre of the FZ
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6.2 Laser-CMT arc hybrid welding of AA6061 alloy

Laser-CMT hybrid welding was developed to join 2-mm thick AA6061 Al alloy by Zhang et al.
Acceptable joints without metallurgy defects were obtained. The cross-weld tensile strength of laser-
CMT hybrid welds was up to 223 MPa, 10 % higher than that of the laser-PMIG hybrid weld. Fig.41
shows the microhardness distributions of transverse joints. The results showed that laser-CMT hybrid
welding could potentially join aluminum alloy thin sheets. Fig.42 depicts the equiaxed dendrites in the
center of the weld fusion zone [55].

6.3 Laser-CMT arc hybrid welding of S420 MC D

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Jan Frostevarg et al. compared the hybrid weld with a close-to-production setup for low and medium
wire deposition rates. Fig.43 displays the High-Speed Image of laser arc hybrid weld pool. They

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concluded that the CMT is suitable for laser hybrid welding of thicker sheets provided the gap is
narrow enough to be filled by the limited wire feed rate. The hybrid weld showed advantages of
higher bead stability, reduced undercut, reduced power supplied, reduced weld/HAZ width and less

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sensitive to speed variations [56].

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Fig.43 High Speed Image of Laser Arc hybrid weld pool

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7. Effect of Base metal and CMT weld Treatments

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7.1 Post weld heat treatment (PWHT) of CMT weld

The effect of PWHT on the mechanical and microstructure properties of welded AA6061 using the
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CMT GMAW was analyzed by Ahmad and Bakar. In their investigation, 3.8% increase was recorded
for tensile strength as observed in Fig.44, hardness strength was increased by 25.6% and a 21.5%
higher elongation was achieved. The results proved that PWHT was able to enhance the hardness
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strength and tensile properties of AA6061 welded joints using the GMAW CMT method. These were
attributed to the fact that PWHT produces a fine and uniform distribution of precipitates at the weld
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joints [57].

Fig.44 Tensile strength of as welded and Fig.45 Microhardness values trend

heat-treated samples
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7.2 Welding steel sheets treated by nitro-oxidation using CMT process

The limited heat input and the controlled metal transfer, which are considered as the main advantage
of the CMT process, had a negative impact on weld joint quality. An excessive amount of porosity
was observed, probably due to the high content of nitrogen and oxygen in the surface layer of the
material and the fast cooling rate of the weld pool. The results show that for steel sheets treated by
nitro-oxidation there was a radical increase in micro hardness values, up to 47%, in comparison with
the values for the same material without surface treatment. After CMT welding, it was observed that
the microhardness values gradually declined from the weld metal till the heat affected zone,

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stabilizing in the base metal as seen in Fig.45. The parameters of the CMT process performed by
Michalec and Maronek were not suitable for welding steel sheets treated by nitro-oxidation, due to the
high level of porosity [58].

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8. Alternative Applications of Cold metal Transfer process

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8.1 Low-dilution cladding of INCONEL 718 superalloy

Microstructural study of INCONEL 718 superalloy clad by Ola and Doern revealed that the clads
were free from porosity and cracking, and complete bonding of the clads with the substrate was

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achieved in all weldments. The outcome of this work showed that the relatively new CMT process,
with the choice of suitable welding parameters, is useful for repair build-up of affected areas of worn-
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out and service damaged components of gas turbines and other high-temperature equipment that are
manufactured from nickel-base superalloys [59].
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8.2 Cladding of Al 6061 alloy

Benoit et al performed Al 6061 clads using Metal inert gas (MIG), pulsed MIG, cold metal transfer
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MIG (CMT) and tungsten inert gas (TIG) welding. The cladding operations were analysed by an
infrared thermal imaging technique and beads were characterized by X-ray radiography, neutron
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diffraction and micro-hardness mapping. The Pulse-Mix CMT process reached higher peak
temperature and produced better quality beads than other MIG processes. The level of residual stress
present in the HAZ of the CMT sample was the highest [60].
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8.3 Cold metal transfer deposited AZ31 magnesium alloy clad

Cold metal transfer (CMT) with low heat input exhibits a great potential for magnesium alloys
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welding as they are susceptible to grain coarsening, pores and hot cracking during welding. In this
paper, Heng Zhang et al. observed the effect of welding speed on microstructures of CMT deposited
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AZ31 magnesium alloy clad. The results demonstrated that to get a qualified cladding of AZ31
magnesium alloy, pulsed-CMT, with an optimal welding speed of 12 mm/s, was preferred [61].

8.4 Al-Si-Mn alloy coating on a commercially pure Al plate

The CMT process can be used as an energy-efficient technique for depositing thick coatings and is
useful in weld repair of aluminum alloy components. Rajeev et al. reported that the bead angle,
deposition rate and dilution are nonlinear functions of the welding speed. Their coating had thickness
greater than 2.5 mm produced in a single pass, which is considerably high compared to thermal spray
processes [62].
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8.5 Wetting of galvanized steel by Al 4043 alloys

Yanlin Zhou and Qiaoli Lin performed the wetting of galvanized steel by 4043 Al–Si alloys under
CMT condition and studied the interfacial structure. The final wettability of this system was mainly
determined by the wettability of Fe by Al (or steel by Al). The residual liquid Zn film after
evaporation cannot improve the final wettability, and also should not be a driving force for spreading
but may be a factor for the contact angle hysteresis. Further, the moving of the triple line (i.e.,
spreading) in this system was limited by the viscosity of the liquid itself [63]. The beneficial role of
Zn coating is the reducing of the heat input, and a thinner intermetallic layer can be obtained [64].

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Qiaoli Lin et al. found that for small wire feed speed, the Leidenfrost effect was caused by Zn
vaporization which induced the non-wetting and welding splatter. The wettability was improved using
large WFS [65, 66].

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8.6 Wetting of Mg AZ61 Alloy/Galvanized Steel in Cold Metal Transfer Process

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The dynamic sessile drop method was used by Qiaoli Lin et al. to investigate the wetting behavior of
galvanized steel by molten Mg AZ61 alloy under cold metal transfer condition. The observed results
showed that the wetting behavior was directly determined by the wire

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feed speed (or the heat input) [67]. AN
8.7 Additive manufacturing of Al-6.3% Cu alloy by CMT process

Baoqiang Cong presented a paper on the effect of arc mode in cold metal transfer (CMT) process on
the porosity characteristic of additively manufactured Al-6.3%Cu alloy. Experiments were performed
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on both single layer deposits and multilayer deposits. The variants of CMT performed in the
experiment were conventional CMT, CMT pulse (CMT-P), CMT advanced (CMT-ADV) and CMT
pulse advanced (CMT-PADV). CMT-PADV proved to be the most suitable process for depositing
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aluminium alloy due to its excellent performance in controlling porosity. The key factors which
enabled this are low heat input, a fine equiaxed grain structure and effective oxide cleaning of the
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wire [68].

8.8 Composite–composite joints reinforced with cold metal transfer welded pins
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Stelzer et al. performed fatigue tests on both Ti CMT and Steel CMT pins used to reinforce Carbon
Fibre Reinforced Polymer (CFRP) sheets. Cold metal transfer welded steel pins proved to be an
effective means for reinforcing CFRP–CFRP SLS joints in the through-the-thickness direction. After
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failure of the bond line between the two CFRP laps, pins carry the loads and maintain the joint’s
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stiffness until final failure. CMT welded titanium pins on the other hand turned out to be less effective
in reinforcing CFRP–CFRP joints. This can be partly ascribed to the lack of a pronounced ballhead-
spike geometry for Ti CMT pins [69].

8.9 Crack repair welding of Steam Turbine Cases by CMT brazing

Cold metal transfer welding was investigated by Kota Kadoi et al. to develop a repair process for
cracks in steam turbine cases, made of Cr-Mo-V cast steel, operated for 188,500h at 566o C. Silver
and gold brazing filler wires were used as overlaying materials. CMT brazing using low melting point
filler wire generally was found to decrease the heat input and peak temperature during the thermal
cycle of the process. The creep-fatigue properties of weldments produced by CMT brazing with BAg-
8 were the highest. Therefore, CMT brazing using low melting point filler wire such as BAg-8 is a
promising candidate method for repairing steam turbine cases [70].
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9. Conclusion

The process, weld combinations and applications of the Cold Metal Transfer welding reported by
various authors are discussed. The main conclusions of this study are:

• The retraction of the wire during the short circuiting phase plays an important role, as it leads
to prevention of spatter generation and also produces better weld bead aesthetics.
• The Laser-CMT hybrid welding produces welds with better mechanical properties and
aesthetics than the Laser welding and Laser-MIG hybrid welding.

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• The Post Weld Heat Treatment (PWHT) caused a positive effect on the welds prepared by
uniformly distributing the fine precipitates, whereas the Nitro-oxidation treatment of the base

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metal prior to welding caused an increase in the level of porosity causing a drastic increase in
the microhardness of the weld.

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• The Cold Metal Transfer Welding has a wide variety of applications such as cladding,
additive manufacturing, composite joint pin fabrication, and crack repair welding.

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