KAKO ODREDITI STABILNOST LUKA?
HOW TO DETERMINE THE ARC STABILITY?
Marjan Suban, Janez Tušek
Adresa autora / Author's address: Institut za varilstvo (Welding Institute), Ptujska 19, 1000 Ljubljana, Slovenia
Ključne reči:
• MIG/MAG zavarivanje
• stabilnost luka
• dinamička karakteristika
Izvod
U radu so prikazane raznolike metode procene
stabilnosti MIG/MAG zavarivanja. Stabilnost procesa
zavarivanja utjiče na zavarljivost i zavisi od
mnogobrojnih parametara. Najnepogodniji rezultati loše
stabilnosti luka su izštrcki, koji su problematični u smislu
gubitka materijala, produženje vremena izrade zbog
dodatnog čiščenja, kao i zbog lošeg izgleda šava.
Metode, koje su opisivane u ovom radu baziraju na
merenju ovisnosti jačine struje zavarivanja i napona
zavarivanja od vremena. Rezultati eksperimentalnog
rada baziraju na analizi stabilnosti električnog luka
sprovedene kod zavarivanja u različitih zaštitnim
atmosferama gasa. Takoñe su uporeñena dva različita
režima zavarivanja. Ispitivana su zavarivanja sa kratkim
lukom i sa prskajučim lukom.
1 INTRODUCTION
The introduction of automation and robotisation in
industry requires real-time monitoring and control of
welding processes. At the same time a more stable
welding processes are required, which ensure a simpler
monitoring and control.
A question is if a simple and rapid method can be found
to assess the process stability. A literature review
indicates several methods. The majority of them are
based on an analysis of the signals provided by a
monitoring system. The monitoring system is based on
real-time measurement of several physical quantities, of
which the two predominating are measurement of
welding current intensity and that of welding voltage [3,
4]. The stability of the welding process can be
determined also on the basis of an analysis of noise
emitted [5] or arc light [6], acoustic emission from a
material or by means of a high-speed camera recording
occurrences in the arc.
In the experimental work described, a comparison of the
above-mentioned methods for the analysis of welding-
process stability on the basis of measurements of
welding current intensity and welding voltage was
made. The results of signal processing and their
Keywords:
• MIG/MAG welding process
• arc stability
• dynamic characteristics
Abstract
The paper treats several methods of evaluating the
stability of MIG/MAG welding processes. The
stability of the welding process influences weldability
and is affected by numerous parameters. The most
unfavourable results of poor arc stability are
spatters which are problematic in terms of material
losses, extension of production times due to
cleaning, as well as unaesthetic appearance. The
methods described in the paper are based on
measurement of time-varying welding current and
welding voltage. The results of the experimental
part of the paper are based on stability analyses
carried out with different gas-shielding
atmospheres. Also two different welding regimes
were compared. The first was short-circuit material
transfer, and the second spraying material transfer.
comparison will be interpreted in terms of welding-
process stability.
2 MATERIAL TRANSFER AND WELDING-PROCESS
STABILITY
Depending on the forces occurring in the arc and, first
of all, welding current intensity, differing material
transfer modes may occur in the welding arc. On the
basis of a study of the phenomenon, the International
Institute of Welding worked out a classification of
material transfer modes [7]. For MIG/MAG welding
processes the following material transfer modes are
characteristic:
• short-circuit transfer,
• drop transfer,
• spray transfer,
• pulse transfer.
The stability of the welding process is a property of the
welding arc. An ideal welding arc, i.e. a stable welding
process, shows the following properties:
• a uniform material transfer,
• with the short-circuit transfer, the arc burning time
and the short-circuit time should be uniform,
• with the spray transfer, time between the transfer of
two subsequent drops should always be the same,
• with the pulsed transfer, the transfer of one drop per
pulse is preferred,
• constant arc length,
• no spatters.
The most unwanted result of poor welding-process
stability are spatters. Spatters are formed of the drops
of molten metal which are not a part of the weld but
solidify at the weld surface. In addition to producing a
loss of material, spatters are unwanted because of a
poorer appearance of the weld. They are a problem not
only for the quality of the weld, but they also influences
the welding equipment negatively. Adhesion of spatters
to a welding nozzle will reduce shielding-gas flow, which
may become turbulent. Cleaning of the welding nozzle
thus is required during the operation, which additionally
extends the production time.
3.1 Dynamic characteristic
Variations in arc length produce variations in welding
current intensity and arc voltage, which is indicated by
the dynamic characteristic of the welding arc (see
Figure 1). The following dependence is thus obtained:
U = f1(t) and I = f2(t)
(1).
In practice the variations in current and voltage occur
very fast and under the influence of various factors such
as electric and thermal conductivity of the arc, electrode
and workpiece, wire-extension length and arc length,
the type of shielding medium used, etc.

The stability of a welding process can be assessed by Figure 1: Dependence of welding current and voltage
the control and analysis of the results obtained with 600 120
measurements. The least complicated and most 500 110
frequently used method of analysis of the welding 400 100

I [A]
300 90
process stability is based on the measurement of the 200 80
dependence of welding current intensity and welding 100 70

voltage on time, which is followed by a statistical 0 60

-100 50
analysis of the signals measured [8, 9, 10]. -200 40

U [V]
-300 30
-400 20
-500 10
3 EXPERIMENTAL PROCEDURE -600 0
0 20 40 60 80 100 120 140 160 180 200
t [ms]
The experiments were focused on measurements of
welding voltage and current in the MIG/MAG welding on time in short-circuit material transfer.
process. Welding was fully automated. Surfacing was
applied to a sheet with a quality of low-alloy structural 3.2 Probability distribution of short-circuit periods
steel. A synergic inverter power source and a suitable and arc burning
automated system for burner guidance were used. A In the short-circuit material transfer, the welding
filler material used was a 1.6 mm solid welding wire of process in the direction of the time axis may be
quality SG 2. Three types of the shielding atmosphere evaluated in the following manner. The short-circuit
were used in the experiments, i.e., pure CO2, a two- transfer welding process may be divided, along the time
component 82% Ar/18%CO2 gas mixture, and a four- axis, into two characteristic phases:
component T.I.M.E. (Transferred Ionized Molten • arc burning time,
Energy) gas mixture (65% Ar/26.5% He/8%CO2/0.5% • short-circuit period.
O2).
The above random variables may be statistically
The measuring part of the system consisted of a shunt, processed and presented in terms of probability
low-pass filters, analogue-to-digital and digital-to- distributions (see Figure 2).
analogue (A/D-D/A) converters, and a personal
computer. The sampling frequency of the measurement
chain was 6 kHz.

600 45
500 40
400
35
I [A]

300
200 30
100
p [%]

25
0
20
tO t KS 50
40 15
U [V]

30 10
20
5
10
0 0
0 20 40 60 80 100 120 140 160 180 200 0 5 10 15 20 25 30 35 40 45 50
t [ms]
t [ms]
KS
 Figure 2: Analysis of arc burning time and short-circuit period.
CO2
tKS [ms]
Figure 3: Probability distribution of short-circuit period with CO2, Ar/CO2, and T.I.M.E shielding gases. I = 90 A, U = 21 V.
Figure 3 shows three diagrams indicating the
differences in short-circuit periods with three differing
shielding gases but with the same other welding
parameters. For pure-CO2 welding the variation of the
curves during the short-circuit periods are smaller than
in the two other cases. Therefore it may be concluded
that the welding process is more stable in this case than
in the other two cases. Two characteristics of the short-
circuit periods in T.I.M.E. are a large dissipation and
two extremes. They both reduce the welding-process
stability.
3.3 Probability distribution of voltage and current
Evaluation of stationary random processes, i.e. of time-
varying welding current and voltage in our case, can be
performed also in the direction of ordinate x(t). In the
direction of the ordinate x(t), a mean value mx, standard
deviation σx, and probability distribution p(x) can be
calculated as shown in Figure 4.
Ar/CO2 T.I.M.E.
tKS [ms] tKS [ms]
Figure 5 shows the probability distribution only for the
welding current intensity but for three differing shielding
gases and with low (medium welding current intensity is
100 A) and high (medium welding current intensity is
430 A) welding parameters. The occurrence of spatters
primarily depends on the welding current intensity. The
higher the welding current intensity in the short circuit,
the stronger the pinch-effect force. Consequently,
breaking of the short-circuit bridge will be more
explosive. The highest welding current intensities in the
short circuit were obtained in welding with the T.I.M.E.
mixture (Figure 5 - left, below), and the lowest,
however, in welding with the pure CO2 (Figure 5 - left,
above). A stronger variation in the probability
distribution with the high welding parameters and pure
CO2 (Figure 5 - right, above) occurs because there is no
spray transfer in this case. Consequently, spattering is
stronger.
 Figure 4: Evaluation of the process in the direction of ordinate x(t).
CO2

p [%]

Ar/CO2

p [%]

T.I.M.E.

p [%]

I [A] I [A]

Figure 5: Probability distribution p(I) with CO2, Ar/CO2, and T.I.M.E. shielding gases.
Left: I = 90 A, U = 21 V; Right: I = 420 A, U = 34 V.

3.4 Fourier analysis N −1

For the process evaluation in the direction of the time F (ω ) = ∑ f ( n ⋅ T ) ⋅ e− j ⋅n ⋅T ⋅ω

n =0
axis, the discrete Fourier transform [11, 13] can be
(2)
used. Signals received from digital processors are
discrete time signals which are defined only at the
where N is the number of samples, T sampling time,
moment of sampling. The discrete Fourier transform
and ω sampling frequency calculated as follows:
F(ω) = F[f(nT)] is a sequence of (complex) samples
{F(ω)} in the frequency space defined by k
ω= , k = 0,1, 2, ... , N - 1
N ⋅T
(3).
 Figure 6 shows a comparison of energy spectra for
The absolute value |F(ω)| of the complex spectrum F(ω) three different shielding gases and low and high welding
is the spectrum of amplitude density of the function parameters. Exceptionally a uniform and stable short-
2
f(nT). The expression |F(ω)| is marked by a symbol circuit material transfer occurs in pure CO2 welding
S(ω), (Figure 6 - left, above). For the T.I.M.E. mixture two
frequencies of short-circuit transfer are characteristic
2 (Figure 6, right, below). As already mentioned, there is
S(ω ) = F (ω )
no spray transfer in CO2 welding. Consequently, there
(4) is no characteristic frequency to be detected (Figure 6,
right, above). The diagram in the right lower corner
and is called an energy spectrum of function f(nT). shows that spray material transfer in the T.I.M.E. gas
mixture is the stablest transfer, the frequency of the
drop transfer being approximately 410 Hz.
CO2

S(ω
ω)

Ar/CO2

S(ω
ω)

T.I.M.E.

S(ω
ω)

ω [Hz] ω [Hz]

Figure 6: Energy spectra of a signal in welding with CO2, Ar/CO2, and T.I.M.E. shielding gases.
Left: I = 90 A, U = 21 V; Right: I = 420 A, U = 34 V.

3.5 Stability analysis based on a cyclogramme
Dynamic processes in the arc may be demonstrated also
in another way, i.e., by cyclogrammes (dynamic
movement of the working point) in Figure 7. A
cyclogramme shows the welding voltage as a function of
the welding current intensity. Cyclogrammes are a very
uncomplicated and fast presentation as far as the
welding process stability is concerned. Monitoring of the
process by means of a cyclogramme may be carried out
in real time.
In short-circuit transfer, two characteristic zones of the
U-I characteristic may be noticed in the cyclogramme.
The arc burning zone is characterised by a higher
welding voltage and a lower welding current intensity,
and the short-circuit period by a low short-circuit voltage
and a higher short-circuit intensity (Figure 7, left, above).
If the three left diagrams in Figure 7 are compared, a
greater stability is observed in welding with the pure CO2
(U-I characteristic occupies a smaller area).
With an increase in welding current intensity, the U-I
characteristic will displace to the upper right corner of
the diagram, which means higher welding voltages and a
higher welding current intensity. In the case of Ar/CO2
and T.I.M.E. mixtures, the spray transfer occurs. In pure
CO2 welding, a smaller number of transfers from the arc
burning zone to the short-circuit zone may be observed.
This considerably reduces arc stability and essentially
increases spattering.

CO2

ARC
U [V]

SHORT-
CIRCUIT

Ar/CO2

U [V]

T.I.M.E.

U [V]

I [A] I [A]

I [A] I [A]

Figure 7: Cyclogrammes for welding with CO2, Ar/CO2, and T.I.M.E. shielding gases.
Left: I = 90 A, U = 21 V; Right: I = 420 A, U = 34 V.

4 CONCLUSIONS The methods described in the paper are based on

measurement of time-varying welding current and
welding voltage. A measurement chain was composed,
experiments were carried out, and a comparison among
three differing gas mixtures and two different welding
regimes was made.
The welding process stability may be determined in
several ways. It was established that stability evaluation
by means of cyclogrammes is extremely uncomplicated
and also fast. Thanks to the process rapidity and
surveyability, a system for monitoring the welding
process in real time can be elaborated.
The comparison of the welding process stability with
three different shielding gases showed that in the case of
short-circuit material transfer, the welding process is
more stable when using the pure CO2, and in the case of
spray transfer, when using the T.I.M.E. mixture. The
T.I.M.E. mixture is for the short-circuit transfer less
suitable since its development was based on high
productivity of the welding process, and consequently
spray material transfer. As regards stability, the common
Ar/CO2 mixture, which is universally applicable,
represents the golden mean.
[9] Dorn L., Rippl P.: Prozeβanalyse beim Metall -
Schutzgasschweiβen - Momentantwertverlauf der
elektrischen Gröβen und Prozeβstabilität bei
Verwendung einer transistorisierten Stromquelle,
Schweiβen und Schneiden, 11 (1984) 526-531.
[10] Gupta S., Rehfeldt D., Seyferth J.: Computerized
evaluation of process stability for gas metal arc
welding, IIW/IIS Doc. 212-611-85 (1985).
[11] Slania W.: Use of Fourier transforms in analysis of
pulsed MAG welding, Welding International, 10
(1997) 761-764.
[12] Dilthey U., Reichel T., Scheller W.: Statistical
process parameter surveillance in GMA welding,
International Journal for the Joining of Materials, 3
(1996) 120-126.
[13] Gyergyek L.: Signali in statistične metode,
Fakulteta za elektrotehniko (Faculty of Electric
Engineering), Ljubljana, (1987).

REFERENCES

[1] Lancaster J. (Ed.): The Physics of Welding,

Pergamon Press,Oxford, (1986).
[2] Rehfeldt D., Seyferth J., Uhlig P.: Statistical
analysis of arc welding processes, IIW/IIS Doc.
212-511-81 (1981).
[3] Rehfeldt D., Bollmann A., Körbe T., Kost N.:
Computer-aided control by process analayzing,
monitoring and documentation, IIW/IIS Doc. 212-
781-91 (1991).
[4] Barrera G., Velez M., Espinosa M., Santos O.,
Gomez G., Barrera E.: Monitoring the submerged-
arc welding (SAW) process using current and
voltage transducers, Welding International, 10
(1997) 795-801.
[5] Grad L.: Sproten nadzor varilnih procesov s
pomočjo akustičnih signalov, Varilna tehnika, 3
(1996) 97-102.
[6] Wang Q., Li P.: Arc light sensing of droplet transfer
and its analysis in pulsed GMAW process, Welding
Journal, 11 (1997) 458s-469s.
[7] N.N.: Classification of metal transfer on arc electric
welding processes, Welding in the World, 5/6
(1977) 113-117.
[8] Dorn L., Rippl P.: Prozeβanalyse beim Metall -
Schutzgasschweiβen - Lichtbogenstabilität,
Spritzerbildung und Momentantwertverlauf der
elektrischen Gröβen bei Veränderung der
Verfahrensparameter, Schweiβen und Schneiden, 5
(1984) 219-224.