The influence of wire feed speed on the electrical characteristics, arc behaviour and droplet transfer in the single power double wire welding process

To investigate the droplet transfer behaviour and electrical characteristics in the context of single power double wire welding, a series of welding process tests were conducted utilizing a self-designed single power double wire welding gun. The study focused on the impact of wire feeding speed on the electrical characteristics and droplet transfer behaviour, while maintaining a consistent filling amount. At a wire feeding speed of 4 m/min, the arc energy was diminished, resulting in predominantly single wire combustion, which was accompanied by the intermittent transfer of the single wire arc. In this scenario, it was easy to make the droplet transfer after short circuiting in contact with the molten pool when the droplet has not yet grown, whose size is small. Conversely, as the wire feeding speed increased, the arc energy also increased, leading to enhanced stability in the simultaneous combustion and droplet transfer of both wires, ultimately resulting in superior overall weld formation. However, the presence of short-circuit transitions and the electromagnetic forces acting on the dual wires contribute to the formation of welding spatter around the weld and on the surface of the preceding weld.