Arc length behaviour and voltage predictions for GMAW-Sp aluminum procedures in the Lincoln Procedure Hand Book

Abstract Heat input is a key component of welding procedure, which dependent on the several fall voltages composing total voltage loss. As current practice primarily reliant trial and error to determine settings for desired heat input, means understand predict loss interest engineers. Voltage, amperage, arc length measurements using ER4043 1.2 mm at varying were used break down constituents given weld with GMAW-Sp. Arc was defined as distance from pool point where metal vapour ionized gas boundary attach consumable, measured over 5 droplet cycles obtain time average. Aluminum procedures in Lincoln Procedure Hand Book (LPHB) 1.2, 1.6, 2.4 consumables analyzed individual experimental results. Expected lengths ranged 13-26 depending prescribed agreed comparative experiments. Combined anode/cathode, column major contributors overall 64±3%, 34±3%, respectively. Contact tip, electrode extension, lead cables minor contributors, each contributing less than 1.2%