Metal Transfer Mapping for Flux-Cored Arc Welding Process by Using Near-Infrared Filming

In the flux-cored arc welding (FCAW) process, the transfer of filler metal to the base material to accomplish the weld bead, determines the weld quality. It must be pointed out that the radiation emitted from the weld arc, fumes and particles (spattering) in this process represent a barrier for these studies based on the process visualization. The objective of this study is to assess metal transfer during the FCAW process of ASTM 1020 steel by filming the phenomena with assistant of near-infrared visualization, contributing to a better understanding of this process and to evaluate characteristics of metal transfer. It can clearly be seen that how the droplet is created and transferred in this process and also identify the different modes of metal transfer by changing the parameters of voltage and wire feed speed in metal transfer maps. Finally, having achieved the metal transfer maps, the suitable condition and approach for developing arc control strategies for the FCAW process were introduced.