metals
Article
Double-Pulse Triple-Wire MIG Welding of 6082-T6 Aluminum
Alloy: Process Characteristics and Joint Performances
Ke Yang 1 , Fei Wang 2,3 , Hongbing Liu 2,3 , Peng Wang 1 , Chuanguang Luo 4 , Zhishui Yu 2,3 , Lijun Yang 1
and Huan Li 1, *






Citation: Yang, K.; Wang, F.; Liu, H.;
Wang, P.; Luo, C.; Yu, Z.; Yang, L.; Li,
H. Double-Pulse Triple-Wire MIG
Welding of 6082-T6 Aluminum Alloy:
Process Characteristics and Joint
Performances. Metals 2021, 11, 1388.
https://doi.org/10.3390/met11091388
Academic Editor: Elena Scutelnicu
Received: 2 August 2021
Accepted: 26 August 2021
Published: 31 August 2021
Publisher’s Note: MDPI stays neutral
with regard to jurisdictional claims in
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iations.
Copyright: © 2021 by the authors.
Licensee MDPI, Basel, Switzerland.
This article is an open access article
distributed under the terms and
conditions of the Creative Commons
Attribution (CC BY) license (https://
creativecommons.org/licenses/by/
4.0/).
Metals 2021, 11, 1388. https://doi.org/10.3390/met11091388
1 Tianjin Key Laboratory of Advanced Joining Technology, Tianjin University, Tianjin 300072, China;
swsyangke@tju.edu.cn (K.Y.); wangpen_g188@163.com (P.W.); yljabc@tju.edu.cn (L.Y.)
2 School of Materials Engineering, Shanghai University of Engineering Science, Shanghai 201620, China;
wangfei@sues.edu.cn (F.W.); lhongbing@163.com (H.L.); yu_zhishui@163.com (Z.Y.)
3 Shanghai Collaborative Innovation Center of Laser Advanced Manufacturing Technology,
Shanghai 201620, China
4 Sichuan Institution of Aerospace Systems Engineering, Chengdu 610100, China; chg_luo@163.com
* Correspondence: lihuan@tju.edu.cn; Tel.: +86-139-2042-6800
Abstract: High-efficiency and high-quality welding has always been the focus of welding research.
This article proposes a novel double-pulse, triple-wire MIG welding process for the welding of
6082-T6 aluminum alloy. The process characteristics of welding arc and droplet transfer were studied,
and the performances of weld formation, morphology, hardness, and tensile strength were tested
for the 1 Hz, 3 Hz, and 5 Hz double-pulse welding and normal-pulse welding. It was found that
in the welding process, the pulsed arc steadily alternated among three welding wires without arc
interruption, and the arc length changed periodically with the double-pulse frequency. The droplets
transferred with a stable one-pulse-one-drop mode. Besides, a proper double-pulse frequency, e.g.,
3 Hz in this case, was conducive to forming good welds with regular fish-scale patterns and no pores.
The tensile strength of the joint could reach 64% of the base material’s tensile strength, and its fracture
belonged to plastic fracture, which occurred in the HAZ. This new welding method will have great
potential in aluminum alloy welding.
Keywords: double-pulse welding; triple-wire welding; 6082 aluminum alloy; welding arc; droplet
transfer; joint performance
1. Introduction
Due to its characteristics of low density, high specific strength, good corrosion re-
sistance, electrical conductivity, thermal conductivity, and good mechanical properties
at low temperatures, aluminum alloy has been widely used in aerospace, automotive,
electrical, chemical, transportation, and other industries [1,2]. The 6082 aluminum alloy,
which belongs to the Al-Mg-Si series, is the main structural material used in high-speed
railway [3,4].
Welding is an important method for joining aluminum alloys. However, because
aluminum alloys have too high thermal conductivity, too large linear expansion coefficients,
and an oxide film on the surface, they are hard to weld. Welding defects, such as incomplete
fusion, slag inclusion, crack, and porosity, easily appear [5].
In recent years, great progress has been made in the research of aluminum alloy weld-
ing. The main welding methods are as follows: friction stir welding (FSW) [6–8], pulsed
metal inert gas (MIG) welding [9], plasma arc welding [10], electron beam welding [11],
laser welding [4,12], and laser-arc hybrid welding [13]. Compared with the other welding
methods, pulse MIG welding has the advantages of low cost and high efficiency, and
therefore it is widely favored in production. Based on pulse MIG welding, double-pulse
MIG welding has been developed by adding low-frequency modulation pulses [14]. The
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Metals 2021, 11, 1388 2 of 13

welding pool is affected by periodic stirring, which facilitates the escape of gas from the
molten pool, thereby reducing the porosity of the weld [15]. Besides, a beautiful fish-scale
weld can be easily obtained [16].
Improving the welding efficiency is also the focus of research. Multi-wire welding is
an effective way to improve welding efficiency, because it can effectively increase heat input
and the amount of wire filling [17–21]. For examples, Ruan et al. [22] proposed double-wire
MIG welding and used it to weld a high-speed train car body structure (6082-T6 aluminum
alloy) with the advantages of fast welding speed, high efficiency, beautiful weld formation,
and small spatter. Recently, Wu et al. [23] proposed double-wire pulsed MIG welding by
adding a median waveform. The AA6061 base metal was welded, and the influence of the
median current on droplet transfer was investigated.
To achieve high-efficiency welding, we developed a novel triple-wire pulse MIG
welding process, where three welding wires were arranged in a torch and powered by three
pulsed power sources (see Section 2.2). The steels, such as Q235 [24] and Q960 [25], were
successfully welded with high efficiency and quality, and the problem of arc interference
was solved by alternating current pulses among the three welding wires [26].
In this study, we extend the triple-wire pulse welding process to the welding of
aluminum alloy. Besides, we introduce the double-pulse characteristic to the welding
process by adding low-frequency modulated pulses in order to improve weld quality. The
double-pulse, triple-wire welding is expected to have the advantages of double-pulse
welding and multi-wire welding. The 6082-T6 plates were successfully welded by this
method, and its process characteristics and joint performances were emphatically studied.
This paper is organized as follows. In Section 2, the double-pulse, triple-wire GMAW
process is introduced. In Section 3, the process characteristics of welding arc and droplet
transfer and the joint performances in terms of weld formation, morphology, hardness,
and tensile strength are presented and analyzed for the welding process with different
double-pulse frequencies. Finally, we summarize this paper in Section 4.

2. Materials and Methods

2.1. Experimental Material
The 6082-T6 aluminum alloy plates (Zhongwang Aluminium Co., Ltd., Liaoning,
China) with dimensions of 200 mm × 100 mm × 8 mm (length × width × thickness)
were used as base material. The ER5356 aluminum wire (Tianjin Golden Bridge Welding
Materials International Trading Co., Ltd., Tianjin, China) with a diameter of 1.2 mm was
used as filler material. Their chemical compositions are shown in Table 1. The mechanical
properties of 6082-T6 aluminum alloy are given in Table 2. Since aluminum alloy is easy to
be oxidized, the workpiece needed to be polished before welding. After that, we wiped it
with alcohol and immediately performed welding.

Table 1. Chemical compositions of the workpiece and wire, data from [27,28].

Aluminum Alloy Mg Si Mn Fe Cu Cr Zn Ti Al
6082-T6 0.83 0.82 0.62 0.24 0.027 0.086 0.024 0.011 Bal.
ER5356 4.5–5.5 0.25 0.05–0.2 0.4 0.1 0.05–0.20 0.01 0.06–0.2 Bal.

Table 2. Mechanical properties of 6082-T6 aluminum alloy, data from [29].

Tensile Strength σ b /(MPa) Yield Strength σ s /(MPa) Elongation ε/(%)

308–315 262–274 10.6–12.2

2.2. Double-Pulse, Triple-Wire MIG Welding Process

Figure 1 shows the experimental system of the double-pulse, triple-wire MIG welding
process. It was divided into three parts: a welding system, a high-speed camera, and an
electrical signal acquisition device. The welding process was performed on the welding
 Metals 2021, 11, 1388 3 of

2.2. Double-Pulse, Triple-Wire MIG Welding Process

Metals 2021, 11, 1388 Figure 1 shows
2.2. the experimental
Double-Pulse, system
Triple-Wire of the
MIG double-pulse,
Welding Process triple-wire MIG weld-
3 of 13
ing process. It was divided into three parts: a welding system, a high-speed camera, and
Figure 1 shows the experimental system of the double-pulse, triple-wire MIG we
an electrical signal acquisition device. The welding process was performed on the welding
ing process. It was divided into three parts: a welding system, a high-speed camera, a
system. The process characteristics
an electrical of welding
signal acquisition arc and
device. Thedroplet
weldingtransfer were
process was studied by
performed on the weld
system.
the The process
high-speed characteristics
camera. The welding of current
weldingand
arc arc
andvoltage
droplet were
transfer were studied
measured by theby the
elec-
system. The process characteristics of welding arc and droplet transfer were studied
high-speed
trical camera. Thedevice.
signal acquisition welding
the high-speed current
camera. Theand arc voltage
welding were
current and measured
arc voltageby themeasured
were electrical by the el
signal acquisition device.
trical signal acquisition device.
Welding Gas
Source 2 Welding Bomb Gas
Source 2 Bomb
Workpiece
Workpiece
A2
A2
U2
Xenon Weld
A1 AU32 Welding Weld
Welding lightWelding Xenon
Welding A1 Source
A3 3
Source 1 U1
U3
Source 3
source light
Source 1 Welding
U1 Torch
U3
source
Welding Torch
(fixed) High-
(fixed) Wire 3 High-
Wire 2 speed Wire 3
Wire 2 speed
camera camera
Z X Y
Z Y
X Wire 1
X
Y
O Y O O X Wire 1
Moving direction O
of workpiece
Moving direction of workpiece

Figure
Figure 1. Schematic
1. Schematic diagram
Figure
diagram of of experimental
the the experimental
1. Schematic system.
diagramsystem.
of the experimental system.

2.2.1.Welding
2.2.1. WeldingSystem
System and Parameters
and Parameters
2.2.1. Welding System and Parameters
AsAs shown
shown in As shown
in Figure
Figure 1, thein
1, the Figure 1,
welding
welding the welding
system
system included
included systemthree
three included three MIG
MIG welding
MIG welding welding machin
machines
machines
(AoTai PulseMIG-500,
(AoTai (AoTai Aotai
PulseMIG-500, PulseMIG-500,
Aotai Electric Co.,
Electric AotaiLtd.,
Co., Electric
Ltd., Co.,
Jinan,
Jinan, Ltd., Jinan,
Shandong,
Shandong, Shandong,
China),
China), China), a homema
aa homemade
homemade
weldingtorch,
welding welding
torch, and
and torch,workbench.
aa welding
welding and a welding
workbench. The
The workbench.
weldingwires
welding The welding
wires wires were
were insulated
were insulated from
from insulated
each from ea
each
other and other
arranged in and
the arranged
welding in the
torch welding
in the torch
form of in
an the form of
equilateral
other and arranged in the welding torch in the form of an equilateral triangle, and they an equilateral
triangle, and triangle,
they and th
were powered by three welding machines, respectively. A standard polarity of electrode of electro
were powered bywere
threepowered
welding by three
machines,welding machines,
respectively. Arespectively.
standard A standard
polarity of polarity
electrode
positivewas
wasused
usedpositivethewas
forthe MIG used for the i.e.,
welding, MIGthe welding, i.e., the
wires were
were thewires
anode,were andthethe
anode, and the workpi
workpiece
positive for MIG welding, i.e., the wires the anode, and the workpiece
wasthe
thecathode.
cathode.Thewas the
Thethree cathode.
threewelding The
weldingmachinesthree welding
machineshad machines
hadaacommunication had a communication
communicationfunction, function,which function,
whichmade madewhich ma
was
a pulse arc alternately on each welding wire, as shown in Figure 2. In the pulse peak sta
aapulse
pulsearc
arcalternately
alternatelyon oneach
eachwelding
weldingwire,wire,as asshown
shownin inFigure
Figure2. 2.In
Inthe
thepulse
pulsepeakpeakstage,
stage,
the arc flashed brightly. In the pulse base stage, the arc was dim. Even due to the brig
thearc
the arcflashed
flashedbrightly.
brightly. InIn the
the pulse
pulse basebase stage,
stage, the
the arc
arc was
was dim. Even Even duedue to to the
the bright
background, the arc was almost invisible, but itdim.
was not broken at thisbright
time.
background, the arc was almost invisible, but it was not
background, the arc was almost invisible, but it was not broken at this time.broken at this time.
10 mm Torch shell
Torch shell (Φ38 mm)
10 mm
(Φ38
Wire mm)
2 Wire 3
Wire 2 Wire 3
Shielding Shooting
gas channel direction
Shielding Shooting
gas channel Wire 1
direction
Wire 1 (a) (b)
(a) 2. Alternating combustion of the pulsed arc among three
Figure (b) wires, (a) arrangement position of welding wires, (b)
welding arcs at different pulse moments.
Figure
Figure 2.
2. Alternating
Alternatingcombustion
combustion ofof
thethe
pulsed
pulsedarcarc
among three
among threewires, (a) (a)
wires, arrangement
arrangementposition of welding
position wires,
of welding (b)
wires,
welding arcsarcs
(b) welding at different pulse
at different moments.
pulse moments.
A double-pulse current was used for each wire. To illustrate its characteristics, Figu
3 compares the electrical signals for normal-pulse mode and double-pulse mode.
AAdouble-pulse
double-pulse current
current was used for for each
each wire.
wire. To
Toillustrate
illustrateits
itscharacteristics,
characteristics,Figure
Figure3
shown in Figure 3, the pulse frequency fp is the inverse of the pulse period Δt. In norm
3compares
comparesthethe electrical signals
electrical for normal-pulse
signals for normal-pulse modemode
and double-pulse mode. mode.
and double-pulse As shownAs
pulse mode, the pulse frequency was almost unchanged, while it changed periodically
in Figure 3, the
shown in Figure 3, pulse frequency f
the pulse frequencyp is the inverse of the pulse period ∆t. In normal-pulse
fp is the inverse of the pulse period Δt. In normal-
double-pulse mode. A double-pulse period can be divided into two stages: strong-pu
mode,mode,
pulse the pulse frequency
the pulse was almost
frequency unchanged,
was almost while itwhile
unchanged, changed periodically
it changed in double-
periodically in
pulse mode. A
double-pulse double-pulse
mode. period can
A double-pulse be divided
period into two into
can be divided stages:
twostrong-pulse group (t1
stages: strong-pulse
stage) and weak-pulse group (t2 stage). The double-pulse frequency f d is the inverse of the
double-pulse period (t1 + t2 ). The pulse frequency in the strong-pulse group was higher
than that in the weak-pulse group, and the pulse peak value and pulse base value in the
strong-pulse group were also slightly higher.
 Metals 2021, 11, 1388 4 of 13

group (t1 stage) and weak-pulse group (t2 stage). The double-pulse frequency fd is the in-
Metals 2021, 11, 1388 verse of the double-pulse period (t1 + t2). The pulse frequency in the strong-pulse group
4 of 13
was higher than that in the weak-pulse group, and the pulse peak value and pulse base
value in the strong-pulse group were also slightly higher.

(a) Normal pulse mode

(b) Double pulse mode

Figure3.3.Electrical
Figure Electricalsignal
signalcharacteristics
characteristicsof
ofnormal-pulse
normal-pulsemode
modeand
anddouble-pulse
double-pulsemode.
mode.

In this
In this study,
study,triple-wire
triple-wirewelding
weldingwith withdifferent
differentdouble-pulse
double-pulse frequencies
frequencies was
was ex-
ex-
plored,
plored,andandititwas
wascompared
comparedwithwithtriple-wire
triple-wirewelding
weldingininnormal-pulse
normal-pulsemode.
mode.The
Thewelding
welding
parameters
parametersare areshown
shownininTable 3. 3.
Table InIn
the table,
the thethe
table, preset voltage
preset andand
voltage preset current
preset refer
current to
refer
the values
to the for for
values a single wire.
a single TheThe
wire. shielding gasgas
shielding waswasargon with
argon a purity
with of 99.99%.
a purity of 99.99%.
Metals 2021, 11, 1388 5 of 13
Metals 2021, 11, 1388 5 of 13

Table 3. Welding parameters for the normal-pulse and double-pulse, triple-wire MIG processes.
Table 3. Welding parameters for the normal-pulse and double-pulse, triple-wire MIG processes.
Double-Pulse Welding
Preset Volt- Preset Cur- Gas Flow
Mode Frequency fd Speed
Preset Voltage U ageCurrent
Preset U (A) I rent IDouble-Pulse
(A) Welding Speed (L/min)
Gas Flow
Mode Frequency f d(Hz) (mm/s)
(A) (A) (mm/s) (L/min)
Normal pulse 18 110 (Hz) - 8 40
Normal pulse 18 110
18 110 - 1 8 8 40
40
Double
18 pulse 18
110 110 1 3 88 40
40
Double pulse 18 110
18 110 3 5 88 40
40
18 110 5 8 40
2.2.2. High-Speed Camera
2.2.2. High-Speed
A MOTION PROCamera
high-speed camera (DEL Imaging Systems, LLC., Woodsville, FL,
USA) wasA MOTION PROthe
used to shoot high-speed camera
welding arc (DEL Imaging
and droplet transferSystems, LLC.,
during the Woodsville,
surfacing FL,
process
ofUSA) was
the flat usedBecause
plate. to shootthe
the arc
welding
is tooarc and droplet
bright, a 1000 Wtransfer
xenonduring the surfacing
lamp source process
(Microenerg
of theTechnology
Beijing flat plate. Because theBeijing,
Co., Ltd., arc is too bright,
China) wasa 1000
used Wto xenon
illuminatelampthe
source
arc to(Microenerg
show the
shadow of the droplets. This method is also known as the shadow method [30].show
Beijing Technology Co., Ltd., Beijing, China) was used to illuminate the arc to Whenthe
shadow of the droplets. This method is also known as the shadow method
shooting, the light source, welding wire, and lens should be kept on the same horizontal [30]. When
shooting,
line. the light
The shooting source, welding
frequency was set towire,
2000and lensper
frames should
second,be kept on the
and the same time
shooting horizontal
was
line. The
set to 3 s. shooting frequency was set to 2000 frames per second, and the shooting time was
set to 3 s.
2.2.3. Electrical Signal Acquisition Device
2.2.3. Electrical Signal Acquisition Device
The electrical signal acquisition device was composed of three CHV-25P Hall voltage
The electrical signal acquisition device was composed of three CHV-25P Hall voltage
sensors (Beijing SENSOR Electronics Co., Ltd., Beijing, China), three CHB-1000S Hall cur-
sensors (Beijing SENSOR Electronics Co., Ltd., Beijing, China), three CHB-1000S Hall
rent sensors (Beijing SENSOR Electronics Co., Ltd., Beijing, China), a NI6251 data acqui-
current sensors (Beijing SENSOR Electronics Co., Ltd., Beijing, China), a NI6251 data
sition card (National Instrument Corp., Austin, TX, USA), and LabVIEW software (Na-
acquisition card (National Instrument Corp., Austin, TX, USA), and LabVIEW software
tional Instrument Corp., Austin, TX, USA). The signals of the welding current and arc
(National Instrument Corp., Austin, TX, USA). The signals of the welding current and
voltage collected by the sensors were transmitted to the acquisition card through a cable.
arc voltage collected by the sensors were transmitted to the acquisition card through a
The sampling error did not exceed 5%. The maximum sampling rate of a single channel
cable. The sampling error did not exceed 5%. The maximum sampling rate of a single
was 1.0 mega
channel was points/second (MS/s). In(MS/s).
1.0 mega points/second this experiment, the sampling
In this experiment, rate wasrate
the sampling set to
was0.1set
MS/s and the sampling time was set to 3 s. In addition, the data acquisition device and
to 0.1 MS/s and the sampling time was set to 3 s. In addition, the data acquisition device the
high-speed camera were
and the high-speed triggered
camera simultaneously
were triggered with a 5 Vwith
simultaneously high-level signal. signal.
a 5 V high-level

2.3. Testing
2.3. Testingofof
Welded
WeldedJoints
Joints
ToTostudy weld formation
study weld formation andand
weld morphology,
weld morphology, we performed
we performed surface surfacing
surface on
surfacing
a flat
on aaluminum plate by
flat aluminum theby
plate triple-wire welding
the triple-wire process.process.
welding The weld formation
The was photo-
weld formation was
graphed with a Canon
photographed EOS 850D
with a Canon EOScamera. The weld
850D camera. The morphology
weld morphology was observed with with
was observed an
OLYPUS
an OLYPUS SZX12 stereomicroscope
SZX12 stereomicroscope (Olympus Corporation,
(Olympus Tokyo,
Corporation, Japan).
Tokyo, Japan).
ToTostudy
studythe
thejoint
jointperformances,
performances, wewedesigned
designed a joint
a jointform
form with
witha aV-shaped
V-shapedgroove
groove
(Figure 4) and performed butt welding. As shown in Figure 4, the groove
(Figure 4) and performed butt welding. As shown in Figure 4, the groove angle α was angle α was 60◦ ,
60°,
the
thethickness
thickness ofof
the
theplates
platest was
t was8 mm,
8 mm,the depth
the depth ofof
the
theroot
rootface
facec was
c was2 mm,
2 mm,and
andthe root
the root
gap
gapb bwaswas2 2mm.
mm.Then,
Then,thethehardness,
hardness,tensile
tensilestrength,
strength,andandfracture
fracturemorphology
morphologyofofthe the
welded
welded joints
joints weretested.
were tested.

c
b

Figure 4. 4.
Figure Groove design
Groove forfor
design butt welding
butt samples.
welding samples.
Metals2021,
Metals 2021,11,
11,1388
1388 66 of
of 13
13
Metals 2021, 11, 1388 6 of 13

The hardness was measured with a micro-hardness tester (Aoka Industry Technology
The hardness was measured with a micro-hardness tester (Aoka Industry Technology Technology
Co., Ltd., Suzhou, China) according to the ISO 9015-1:2001 standard (Destructive tests on
Co.,
Co., Ltd., Suzhou,
Suzhou, China)
China)according
accordingtotothe theISO
ISO9015-1:2001
9015-1:2001 standard (Destructive tests
welds in metallic materials—Hardness testing—Part 1: Hardness test on arc tests
standard (Destructive weldedon
on welds in metallic materials—Hardness testing—Part 1: Hardness
welds in metallic materials—Hardness testing—Part 1: Hardness test on arc welded test on arc welded
joints). The test locations, which were located at the middle depth of the plate thickness,
joints).
joints). The
Thetest
testlocations,
locations,which
whichwerewerelocated
located at at
thethe
middle
middle depth of the
depth plate
of the thickness,
plate are
thickness,
are marked with red dots in Figure 5. Since the hardness distribution of the joint is sym-
marked
are markedwith red
with dots in Figure 5. Since the hardness distribution of the joint is symmetrical
metrical
with with
the with the red
centerline
dots inof
centerline Figure
of the weld, the 5. Since
weld,
theweld,
the hardness
the hardness
hardness test
test wastest
distribution
was carried
carried out with
of the
out with
the
joint
theiscenter
center
sym-
metrical the centerline of the the hardness was carried out with the of the
center
of theasweld
weld as the starting
the starting point.
point. The The interval
interval between
betweenbetween two adjacent
two adjacent points waspoints was
0.25 was 0.25
mm,0.25 mm,
the load
of the
the loadweld
was as the starting
500 gf,loading point.
and the loading The interval
time was 15 s. two adjacent points mm,
was 500 gf,
the load was and500the
gf, and thetime was time
loading 15 s. was 15 s.

t
t
t/2
t/2

Figure 5. Schematic diagram of hardness test locations.

Figure 5.
Figure 5. Schematic
Schematic diagram
diagram of
of hardness
hardness test
test locations.
locations.
The tensile strength was measured with a DDL300 electronic universal testing ma-
The
The tensile
tensilestrength
strengthwas
wasmeasured
measured with a DDL300
with a DDL300electronic universal
electronic testing
universal machine
testing ma-
chine (CIMACH, Changchun, Jilin, China) according to the ISO 4136:2012 standard (De-
(CIMACH,
chine Changchun,
(CIMACH, Jilin, China)
Changchun, Jilin, according
China) to the ISO
according to 4136:2012
the ISO standardstandard
4136:2012 (Destructive
(De-
structive tests on welds in metallic materials—Transverse tensile test). The tensile speci-
tests on welds
structive tests in
onmetallic
welds inmaterials—Transverse tensile test).
metallic materials—Transverse The tensile
tensile specimen
test). The tensilesize is
speci-
men size is given in Figure 6. Then, the microscopic morphology of the fracture was pho-
given in Figure 6. Then, the microscopic morphology of the fracture was photographed
men size is given in Figure 6. Then, the microscopic morphology of the fracture was pho-
tographed with a SU1510 scanning electron microscope (Hitachi Co., Ltd., Tokyo, Japan).
with a SU1510
tographed withscanning
a SU1510 electron
scanningmicroscope (Hitachi Co.,(Hitachi
electron microscope Ltd., Tokyo, Japan).
Co., Ltd., Tokyo, Japan).
mm
3737 mm

80 mm
80 mm

Figure 6. Schematic diagram of the tensile specimen size.

Figure
3. 6. Schematic
Results diagram of the tensile specimen size.
and Discussion
Figure 6. Schematic diagram of the tensile specimen size.
3.1. Welding Arc and Droplet Transfer
3. Results and Discussion
3. Results
Weldingandarc
Discussion
and droplet transfer are important welding process characteristics, which
3.1. Welding
directly Arc andwhether
determine Droplet Transfer
the welding process is good. Through the analysis of high-
3.1. Welding Arc and Droplet Transfer
speedWelding
camera andarc and droplet
electrical transfer
signals, arefound
it was important welding process
that regardless characteristics,
of normal-pulse mode
Welding arc and droplet transfer are important welding process characteristics,
which directly determine whether the welding process is good. Through
or double-pulse mode, the pulse arc of triple-wire welding can alternate steadily among the analysis of
which directly determine whether the welding process is good. Through the analysis of
high-speed
three wires. camera
During and electricalprocess,
the welding signals,there
it waswasfound
no arcthat regardless and
interruption, of normal-pulse
the droplet
high-speed camera andmode,
mode ormaintained
double-pulse electrical signals,
the pulse arcitof
was found that
triple-wire regardless of normal-pulse
transfer a stable one-pulse-one-drop mode. welding can alternate
The welding steadily
arc and droplet
mode or double-pulse mode, the pulse arc of triple-wire welding can alternate steadily
among three
transfer duringwires. During
the flat the welding
surfacing process,
process were there was
observed. no arc
Figure interruption,
7 shows and arc
the welding the
among
droplet
and three
droplet wires.
transfer During
maintained
transfer for athe welding
stable process, there
one-pulse-one-drop
the double-pulse, triple-wire was
mode.
welding no arcwelding
The
process interruption, and
arc and the
drop-
with a double-pulse
droplet transfer
frequency maintained a stable one-pulse-one-drop mode. The welding arc and drop-
let transferofduring
3 Hz asthe
anflat
example.
surfacing process were observed. Figure 7 shows the welding
let transfer during the flat surfacing process were observed. Figure 7 shows the welding
arc and droplet transfer for the double-pulse, triple-wire welding process with a double-
arc
pulseand droplet transfer
frequency of 3 Hz for theexample.
as an double-pulse, triple-wire welding process with a double-
pulse frequency of 3 Hz as an example.
Metals 2021, 11, 1388 7 of 13
Metals 2021, 11, 1388 7 of 13

1 2 3 4 5 6 7

8 9 10 11 12 13 14

123 4 5 6 789 1011 1314

12

U1/V 30
20
10
400
I1/A

200
0
30
U2/V

20
10
400
I2/A

200
0
30
U3/V

20
10
400
I3/A

200
0
0.55 0.56 0.57 0.58
t/s
Figure7.7.Welding
Figure Weldingarc arcandanddroplet
droplettransfer
transferin
inthe
thedouble-pulse,
double-pulse,triple-wire
triple-wirewelding
weldingprocess
process(double-
(double-
pulse frequencyf dfd == 33 Hz).
pulsefrequency Hz).

The
Theabove
aboveresults
results areare
mainly determined
mainly determined by the
bycharacteristics
the characteristics of the ofalternating pulse
the alternating
of the three-wire
pulse welding.
of the three-wire The main
welding. problem
The main of multi-wire
problem welding
of multi-wire is theisinterference
welding the interfer-
between arcs. Severe
ence between arc interference
arcs. Severe may cause
arc interference mayarc interruption,
cause which inwhich
arc interruption, turn affects
in turntheaf-
droplet transfer. Our previous study [25] found that when the three
fects the droplet transfer. Our previous study [25] found that when the three arcs are al- arcs are alternately
pulsed, thepulsed,
ternately arc interference is the smallest,
the arc interference is the while whenwhile
smallest, the two arcsthe
when aretwoin the pulse
arcs are stage
in the
and one
pulse arc is
stage andin one
the base
arc isstage,
in thethe arcstage,
base interference is the largest.isIn
the arc interference thethis study,Inalthough
largest. this study,a
double-pulse mode was added,
although a double-pulse mode it stilladded,
was retained the retained
it still characteristics of an alternating
the characteristics of anpulse
alter-
for eachpulse
nating arc. Therefore,
for each arc. theTherefore,
interference
the between
interference arcsbetween
was small arcsandwas the welding
small and theprocess
weld-
was stable.
ing process was stable.
Nevertheless,
Nevertheless,the thedouble-pulse
double-pulse arcarcstill hashas
still a feature
a featurethatthat
is different fromfrom
is different an ordinary-
an ordi-
pulse
nary-pulse arc, that is, the arc length changes periodically. Figure 8 shows the lengths
arc, that is, the arc length changes periodically. Figure 8 shows the arc arc lengthsat
the pulse
at the peakpeak
pulse momentmoment during a double-pulse
during a double-pulse stage stage
for thefor3 Hzthedouble-pulse
3 Hz double-pulsefrequency.fre-
The arc on wire 1 was paid special attention. When the current
quency. The arc on wire 1 was paid special attention. When the current pulse changed pulse changed from the
strong-pulse group to thegroup
from the strong-pulse weak-pulse
to the group (stage group
weak-pulse A: 0.530–0.681
(stage A: s),0.530–0.681
the arc length s),ofthe
wire
arc
1length
gradually became longer. When the current pulse changed from
of wire 1 gradually became longer. When the current pulse changed from the weak-the weak-pulse group to
the strong-pulse group (stage B: 0.690–0.824 s), the arc length gradually
pulse group to the strong-pulse group (stage B: 0.690–0.824 s), the arc length gradually became shorter.
The shorter.
became reason for the periodic change in the arc length was that the welding wire feeds at a
constant speed
The reason butformelts at an unequal
the periodic change speed.
in theAccording
arc lengthtowas arc–anode
that theheat transfer
welding wiretheory,
feeds
the melting rate of the welding wire is proportional to the welding current [31]. From
at a constant speed but melts at an unequal speed. According to arc–anode heat transfer
the weak-pulse group to the strong-pulse group, the average welding current increased
theory, the melting rate of the welding wire is proportional to the welding current [31].
as the pulse frequency increased, which led to an increase in the welding wire melting
From the weak-pulse group to the strong-pulse group, the average welding current in-
rate, but the welding wire feed speed did not change, so its arc length increased. From the
creased as the pulse frequency increased, which led to an increase in the welding wire
strong-pulse group to the weak-pulse group, the same was true.
melting rate, but the welding wire feed speed did not change, so its arc length increased.
From the strong-pulse group to the weak-pulse group, the same was true.
Metals 2021, 11, 1388 8 of 13
Metals 2021, 11, 1388 8 of 13

t=0.530s t=0.553s t=0.573s t=0.589s t=0.603s t=0.616s

From weak pulse group to strong

pulse group
t=0.629s t=0.640s t=0.651s t=0.661s t=0.672s t=0.681s

Stage A Stage B

t=0.690s t=0.699s t=0.708s t=0.718s t=0.728s t=0.739s

From strong pulse group to weak
pulse group

t=0.751s t=0.763s t=0.776s t=0.791s t=0.807s t=0.824s

Figure 8. Arc length change during the double-pulse, triple-wire welding process (double-pulse
Figure 8. Arc length change during the double-pulse, triple-wire welding process (double-pulse
frequency fd = 3 Hz).
frequency f d = 3 Hz).

3.2.Joint
3.2. JointPerformances
Performances
3.2.1.
3.2.1.Weld
WeldFormation
Formationand andMorphology
Morphology
Figure
Figure99shows
showsthetheweld
weldformations
formations ofofthe
thesurfacing process
surfacing process forfor
thethe
three-wire
three-wirewelding
weld-
processes withwith
ing processes the normal
the normalpulse andand
pulse the the
double pulses
double (f d (f=d 1,
pulses 3, 3,
= 1, 5 Hz).
5 Hz).ItItwas
wasfound
found
that
thatthetheweld
weldsurface
surfaceofofall
allthe
thewelding
weldingprocesses
processeswas wasbright.
bright.Obvious
Obviousfish-scale
fish-scalepatterns
patterns
were
were observed on the weld seams for the double-pulse welding. With thethe
observed on the weld seams for the double-pulse welding. With increase
increase in
in the
the double-pulse frequency, the scale pattern gradually became denser.
double-pulse frequency, the scale pattern gradually became denser. The formation of fish- The formation
of fish-scale
scale patterns
patterns was related
was related to the periodic
to the periodic impact ofimpact of droplets
droplets on the molten on the molten
pool. The pool.
drop-
The droplet frequency
let transfer transfer frequency
was highwas high
in the in the strong-pulse
strong-pulse group, while group, while
it was lowit in
was
thelow in
weak-
the weak-pulse group. Therefore, the impact of droplets was periodic.
pulse group. Therefore, the impact of droplets was periodic. On the whole, the fish-scale On the whole, the
fish-scale
pattern was pattern was the
the most most beautiful
beautiful for the 3 Hzfor the 3 Hz double-pulse
double-pulse frequency. frequency.
Figure
Figure 10 compares the weld morphology of the surfacing process for
10 compares the weld morphology of the surfacing process for the
the normal-
normal-
pulse
pulse welding and the double-pulse welding (fdd = 3 Hz). The weld width and welddepth
welding and the double-pulse welding (f = 3 Hz). The weld width and weld depth
of
ofthe
thenormal-pulse
normal-pulsewelding
welding were
were9.91
9.91mm mmand and1.69
1.69mm,
mm,respectively,
respectively,while whilethey
theywere
were
10.55 mm and 2.54 mm, respectively, for the double-pulse welding.
10.55 mm and 2.54 mm, respectively, for the double-pulse welding. The increase in weld The increase in weld
width and depth for the double-pulse welding may come from stronger agitation of the
width and depth for the double-pulse welding may come from stronger agitation of the
molten pool, which originated from the periodic impact of droplets. The stirring effect
molten pool, which originated from the periodic impact of droplets. The stirring effect of
of the molten pool is also conducive to eliminating pores. As shown in Figure 10, the
the molten pool is also conducive to eliminating pores. As shown in Figure 10, the pores
pores in the double-pulse weld were significantly less than those in the normal-pulse weld.
in the double-pulse weld were significantly less than those in the normal-pulse weld.
Therefore, double-pulse welding has obvious advantages over normal-pulse welding in
Therefore, double-pulse welding has obvious advantages over normal-pulse welding in
eliminating porosity.
eliminating porosity.
Metals 2021, 11, 1388 9 of 13
Metals 2021, 11, 1388 9 of 13

Figure 9.
Figure 9. Weld
Weldformation
formationfor
fordifferent
differentwelding
welding models:
models: (a)(a) normal
normal pulse;
pulse; (b)(b) double
double pulse,
pulse, 1 Hz;
1 Hz; (c) double
(c) double pulse,
pulse, 3 Hz;3 and
Hz;
and (d) double pulse,
(d) double pulse, 5 Hz. 5 Hz.

Figure10.
Figure 10. Comparison
Comparison of
of weld
weldmorphology
morphologyfor
for(a)
(a)normal-pulse
normal-pulsewelding
weldingand
and(b)
(b)double-pulse
double-pulsewelding
welding(f(fddd == 33 Hz).
Hz).

3.2.2. Weld
3.2.2. Weld Hardness
Hardness
Figure 11
Figure 11 shows
shows the
the weld
weld hardness
hardness distribution
distribution for
for the
the normal-pulse
normal-pulse welding
welding and
and the
the
double-pulse welding (f = 1, 3, 5 Hz). Their hardness distribution followed the same
double-pulse welding (fddd= 1, 3, 5 Hz). Their hardness distribution followed the same law: law:
there were
there were two
two troughs,
troughs, which
which were
were in
in the
the center
center of
of the
the weld (L ≈
weld (L ≈ 00 mm)
mm) and
and in
in the
the heat
heat
effect (L ≈
effect zone (L ≈ 15 mm). In other words, the welded joint has two joint-softening zones:zones:
zone 15 mm). In other words, the welded joint has two joint-softening weld
and heat-affected zone (HAZ). This phenomenon was in line with the general law of the
Metals 2021, 11, 1388 10 of 13
Metals 2021, 11, 1388 10 of 13

weld and heat-affected zone (HAZ). This phenomenon was in line with the general law of
joint softening
the joint for the
softening forarc
thewelding of age-strengthened
arc welding aluminum
of age-strengthened alloy [5].
aluminum alloyIt was also
[5]. It found
was also
that
foundthethat
lowest hardness
the lowest value appeared
hardness in the weld
value appeared forweld
in the the normal-pulse weldingwelding
for the normal-pulse and the
5and
Hzthedouble-pulse welding,welding,
5 Hz double-pulse while it appeared in the HAZ
while it appeared forHAZ
in the the 1for
Hztheand1 3Hz Hzanddouble-
3 Hz
pulse welding.welding.
double-pulse

Figure 11. Hardness

Figure 11. Hardness distribution
distribution under
under different
different welding
welding conditions: (a) normal
conditions: (a) normal pulse;
pulse; (b)
(b) double
double pulse,
pulse, 11 Hz;
Hz; (c)
(c) double
double
pulse, 3 Hz; and (d) double pulse, 5 Hz.
pulse ,3 Hz; and (d) double pulse, 5 Hz.
3.2.3. Tensile Strength
3.2.3. Tensile Strength
Figure 12 shows the tensile strength and fracture location of the weld joints for the
Figure 12 shows the tensile strength and fracture location of the weld joints for the
normal-pulse welding and the double-pulse welding (f d = 1, 3, 5 Hz). The tensile strengths
normal-pulse welding and the double-pulse welding (fd = 1, 3, 5 Hz). The tensile strengths
of the specimens were 198.57 MPa, 200.92 MPa, and 189.03 MPa for the 1 Hz, 3 Hz, and 5 Hz
of the specimens
double-pulse were respectively.
welding, 198.57 MPa, These
200.92values
MPa, andwere189.03
higherMPathanfor
thethe 1 Hz,
value of 3185.12
Hz, and
MPa5
Hz double-pulse welding, respectively. These values were higher than
for the normal-pulse welding. The samples fractured at the weld for the normal-pulse the value of 185.12
MPa
weldingfor and
the the
normal-pulse welding.welding,
5 Hz double-pulse The samples
while fractured at the
they fractured at weld
the HAZ for the normal-
for the 1 Hz
pulse welding and the 5 Hz double-pulse welding, while they fractured
and 3 Hz double-pulse welding. These fracture characteristics were consistent with the at the HAZ for
the 1 Hz and 3 Hz double-pulse
hardness distribution shown in Figure 11.welding. These fracture characteristics were consistent
with For
the hardness
normal-pulsedistribution
welding,shown in Figure
there are many 11.pores in the weld, as shown in Figure 13.
For normal-pulse welding, there are many
The existence of pores weakens the strength of the weld, pores in the weld,the
causing as shown
sampleintoFigure
break 13.
on
The existence of pores weakens the strength of the weld, causing the
the weld instead of the HAZ. For the double-pulse welding, an appropriate double-pulsesample to break on
the weld instead
frequency of 3 Hzofcan
theeffectively
HAZ. Forreduce
the double-pulse
weld porositywelding,
and itsan appropriate
fracture double-pulse
is a ductile fracture
frequency of 3 Hz can effectively reduce weld porosity and its fracture is a ductile
that occurs in the HAZ. Its tensile strength (200.92 MPa) can reach 64% of the base material’s fracture
that occurs
tensile in the
strength HAZ. Its
(308–315 tensile
MPa), whichstrength (200.92
can meet MPa)requirements.
general can reach 64% of the base mate-
rial’s tensile strength (308–315 MPa), which can meet general requirements.
Metals 2021, 11,
Metals 2021, 11, 1388
11, 1388
1388 11 of
11
11 of 13
of 13

Figure 12. Tensile

Figure 12.
Figure 12. Tensilestrength
Tensile strengthand
strength andfracture
and fracturelocation
fracture ofof
location
location weld
of joints
weld
weld forfor
joints
joints thethe
for normal-pulse
the welding
normal-pulse
normal-pulse andand
welding
welding the
and
double-pulse
the
the welding
double-pulse
double-pulse (f d =(f
welding
welding (fdd1,==3,1,
1,53,3,Hz).
55 Hz).
Hz).

Figure 13. Fracture

Figure 13.
Figure microscopic
Fracture microscopic
Fracture morphology
microscopicmorphology
morphologyofof weld
ofweld joints
weldjoints for
jointsfor (a)
for(a) the
(a)the normal-pulse
thenormal-pulse welding
normal-pulsewelding and
weldingand (b)
(b)f dffdd===111Hz,
and(b) Hz, (c)
(c)f ffddd =
Hz,(c) = 33 Hz,
Hz,
and
and (d)
(d) f
f d
d =
= 5
5 Hz
Hz double-pulse
double-pulse welding
welding processes.
processes.
and (d) f d = 5 Hz double-pulse welding processes.

4.
4. Conclusions
Conclusions
Compared
Compared with
withtriple-wire
with triple-wireMIG
triple-wire MIGwelding
MIG welding
welding with
with normal-pulse
with normal-pulse
normal-pulse mode, double-pulse,
mode,
mode, tri-
double-pulse,
double-pulse, tri-
triple-wire
ple-wire MIGMIG welding
welding with
with a a proper
proper double-pulse
double-pulse frequency
frequency (e.g.,
(e.g., 3 Hz3 Hz
in in
this this
case)
ple-wire MIG welding with a proper double-pulse frequency (e.g., 3 Hz in this case) can case)
can
can obtain good process characteristics and joint performances for the welding of 6082-T6
Metals 2021, 11, 1388 12 of 13

aluminum alloy. The pulse arc stably alternated among three welding wires without arc
interruption, and the droplets transferred with a stable one-pulse-one-drop mode. The
weld seam was shaped into a beautiful fish-scale pattern, and there were few pores in
the weld. During the stretching process, the fracture occurred in the HAZ, which belongs
to plastic fracture. The tensile strength of the joint can reach 64% of the base material’s
tensile strength. Due to its overall performance, this method will have great potential in the
welding of aluminum alloys. In the future, we plan to gradually use it in actual production.

Author Contributions: Conceptualization, K.Y. and H.L. (Huan Li); methodology, K.Y., P.W. and
F.W.; software, F.W. and H.L. (Hongbing Liu); validation, K.Y., H.L. (Hongbing Liu) and F.W.; formal
analysis, K.Y. and H.L. (Huan Li); investigation, K.Y. and C.L.; resources, H.L. (Huan Li), L.Y. and
F.W.; data curation, K.Y. and Z.Y.; writing—original draft preparation, K.Y. and F.W.; writing—review
and editing, F.W.; visualiza-tion, K.Y. and F.W.; supervision, H.L. (Huan Li); project administration,
K.Y.; funding acquisition, H.L. (Huan Li) and F.W. All authors have read and agreed to the published
version of the manuscript.
Funding: This research was funded by the National Natural Science Foundation of China (grant nos.
51675375 and 52005320).
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Not applicable.
Conflicts of Interest: The authors declare no conflict of interest.

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