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An improved method of gas metal arc welding (GMAW) is disclosed. The method includes utilizing a pulsed current having a variable waveform to ensure the detachment of one-droplet-per-pulse of current. During the welding process, the current is sufficient to produce a droplet at the end of a consumable electrode wire. After the droplet reaches a desired size, the current is lowered to induce an oscillation in the droplet. The current is then increased which, in combination with the momentum created by the oscillation, effects droplet detachment. The oscillation may be monitored by observing the arc voltage to determine a preferred detachment instant. A computer implemented method allows for the adaptive control of the current waveform to accommodate for anticipatable variations in the welding conditions, while maintaining ODPP transfer and a constant pulse period. An accompanying system is disclosed for implementing the method of adaptive welding.


University of Kentucky Research Foundation, Lexington, Ky.

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