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Fume Generation in Al-Mg Alloy Welding with AC-pulsed GMA Welding Method

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A novel AC-pulsed GMA inverter welder has been developed to reduce the weld fumes, generated from the overheated droplets of filler metal wire, which contain high vapor pressure alloying elements. In the fume collection experiment with our new welder, the effects of alloying, components both in solid wire and base metal on fume generation have been studied with different combinations of welding materials. We have found that Mg in the wire is the main fume generation source in DCEP-pulsed GMA welding of an Al-Mg alloy, and our AC-pulsed GMA inverter welder can suppress its effect satisfactorily. The effects of welding parameters (welding current, arc voltage, etc.) on fume generation have also been investigated. X-ray diffraction has been used to identify the compositions of fumes collected under different welding conditions. After observing droplet transfer with an ultra-high speed video camera, fume generating phenomena and mechanisms of fume suppression are discussed.


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