Design and Experimental Analysis of a High-Power Generator for Gas

Metal Arc Welding in Spray Transfer Mode

ADNAN MUHAMMED ALI HAKKI1, SID AHMED EL MEHDI ARDJOUN2,*

1FGBOU VO "Financial University under the Government of the Russian Federation",

Moscow,

RUSSIA

2IRECOM Laboratory, Faculty of Electrical Engineering,

Djillali Liabes University, Sidi Bel-Abbes 22000,

ALGERIA

*Corresponding Author

Abstract: - This article presents the design and experimental analysis of a high-power generator dedicated to the

Gas Metal Arc Welding (GMAW) process in spray transfer mode. The proposed system uses an H-bridge

inverter based on insulated gate bipolar transistors (IGBT), controlled by an LM5046 integrated circuit to

ensure pulse width modulation (PWM) control at a switching frequency of 30 kHz. The generator operates at

three key power points with output currents of 150A, 200A, and 250A, and respective pulse widths of 10μs,

13μs, and 17μs. ER70S-7 electrodes of different diameters (0.035", 0.045", 0.065") were used for each current

level. The welding system is optimized to maintain stable spray transfer, minimizing spatter and improving the

quality of the weld bead. A current-limiting network consisting of a 10μH inductance and a variable 10Ω

resistor ensures output current regulation. This work focuses on the experimental study of the generator's

behavior in spray transfer mode, demonstrating its effectiveness for industrial applications in welding thick

materials.

Key-Words: - Gas metal arc welding, Spray transfer mode, H-bridge inverter, IGBT Transistors, High power

generator, PWM controller.

Received: April 6, 2024. Revised: August 7, 2024. Accepted: October 7, 2023. Published: November 14, 2024.

1 Introduction

Gas Metal Arc Welding (GMAW) is one of the

most widely used welding processes in modern

industry due to its ability to produce high-quality

welds quickly and efficiently, [1], [2], [3], [4]. This

process uses an electric arc to melt a wire electrode,

transferring molten metal to the workpiece, [5].

Depending on the welding parameters, there are four

main modes of metal transfer: short-circuit transfer,

globular transfer, pulsed transfer, and spray transfer,

[6]. Among these, spray transfer is particularly

favored for welding thick materials due to its ability

to transfer metal in small droplets with minimal

spatter, ensuring high weld quality, [7].

The spray transfer mode requires high current

and tightly controlled voltage parameters, which

impose specific demands on the welding power

supply. To ensure continuous and stable spray

transfer, it is essential to have a power source

capable of delivering precise pulses at high power

levels, [8], [9], [10], [11], [12]. The design of such

generators must also incorporate current-limiting

components to prevent overvoltage conditions that

could affect weld quality, [13].

Despite the numerous advantages of the spray

transfer mode, few studies have explored the

detailed design and performance of high-power

generators for this welding method. There is a

pressing need to develop systems capable of reliable

operation under demanding industrial conditions,

particularly for thick materials used in construction,

automotive, and heavy manufacturing sectors.

This article proposes then the design and

experimental analysis of a high-power generator

specifically designed for GMAW in spray transfer

mode. The generator is based on an H-bridge

inverter using insulated gate bipolar transistors

(IGBT) controlled by an LM5046 integrated circuit

to ensure stable pulse width modulation (PWM) and

precise output currents. The primary goal is to

evaluate the performance of this generator at three

different power levels (150A, 200A, 250A) and to

WSEAS TRANSACTIONS on ELECTRONICS

DOI: 10.37394/232017.2024.15.9

Adnan Muhammed Ali Hakki,

Sid Ahmed El Mehdi Ardjoun

E-ISSN: 2415-1513

Volume 15, 2024

validate its effectiveness in achieving stable spray

transfer with minimal spatter.

2 Experimental Procedure

The welding machine used in this study is composed

of several main components: a three-phase voltage

source (220V, 50Hz), a full bridge rectifier unit, a

low-pass filter (LPF), an H-bridge inverter unit, and

a load unit with a current limiter (Ls, Rs), as

illustrated in the block diagram (Figure 1,

Appendix) and the schematic circuit (Figure 2,

Appendix).

Figure 2 (Appendix) shows the schematic

circuit of the three-phase welding machine. Figure 3

(Appendix) shows the equivalent circuit of the

three-phase welding machine.

The H-bridge inverter unit consists of four N-

channel insulated gate bipolar transistor (IGBT)

modules (MG12200D-BA1MM). The diodes (D7,

D8, D9, D10) in the inverter unit are built-in diodes

that come with the IGBT modules. All four modules

(Q1, Q2, Q3, Q4) operate as switches (on-off), with

a switching frequency of 30kHz. The maximum

duty cycle of the Gate-Emitter square signal is 50%,

and the Gate-Emitter voltage for the modules is

15V. The shielding gas mixture used during welding

is 95% Argon and 5% Oxygen. Table 1 (Appendix)

lists the primary technical specifications of the

MG12200D-BA1MM IGBT module, [14].

The plasma discharge regimes observed include

dark discharge, glow discharge, and arc discharge,

as shown in Figure 4 (Appendix). The welding

machine operates in the arc discharge regime

(Thermal arc). In this regime, the current is directly

proportional to the voltage, and the thermal arc

temperature can range from approximately 3000°C

(5500°F) to over 20,000°C (36,000°F), [15].

Figure 5 (Appendix) shows the Spry GMAW

drop transfer mode. The CTWD (contact tip-to-

work piece distance) was 16 mm in all

measurements.

The welding machine initiates an electric arc

between the electrode wire and the workpiece,

generating intense heat that melts both the wire and

the base material. In spray transfer mode, the current

is set at a higher level—typically above 25-30 volts

and in the range of 150 to 400 amps—allowing for a

stable arc and facilitating the formation of fine

droplets of molten metal. Unlike globular transfer,

spray transfer produces a continuous stream of small

molten droplets, which are propelled across the arc

by electromagnetic forces. This result in a smoother,

more controlled weld with minimal spatter. As the

high temperature rapidly melts the electrode wire,

the fine droplets are sprayed across the arc and into

the weld pool, where they solidify to create a strong,

high-quality weld. The shielding gas mixture (95%

argon, 5% oxygen) flows through the welding torch,

enveloping the arc and weld area. This gas layer

protects the molten weld pool from oxidation and

contamination, ensuring the integrity of the weld,

[16], [17].

3 Results

To improve the waveform quality, it is essential to

fine-tune the PWM settings, [18], [19]. For this

reason, the LM5046 IC, which generates PWM

pulses, is chosen for control. The IC controls the

system's output current, which is directly

proportional to the on-time of the transistor

modules, also known as the Power Transfer Time.

The width of the PWM pulses determines the output

current.

Figure 6 (Appendix) illustrates three basic

operating points. The first is an output current of

150A with a 10µs pulse width, using a 0.035-inch

ER70S7 wire, [20]. The second is 200A at a 13µs

pulse width, utilizing a 0.045-inch ER70S7 wire,

while the third point achieves 250A at a 17µs pulse

width with a 0.062-inch ER70S7 wire. The average

load current (Io) ranges between 150A and 250A.

Figure 7 (Appendix) shows the output current at a

10µs pulse width.

ER70S7 is a versatile GMAW wire suitable for

various carbon steel welding applications. With

higher manganese content, it offers improved

wetting and a better weld appearance, along with

slightly enhanced tensile and yield strengths. For

optimal performance in the spray GMAW drop

transfer mode, the appropriate wire diameter must

be selected based on the welding current. Table 2

(Appendix) outlines the key technical parameters for

spray GMAW operation.

The frequency response curve clearly

demonstrates that the designed generator operates

over a wide switching frequency range. The

LM5046 IC generates PWM pulses with variable

widths at each selected switching frequency within

the range of 10 kHz to 40 kHz as shown in Figure 8

(Appendix). These pulses are directly proportional

to the required welding current, ensuring precise

control over the output. Additionally, the IC

maintains a fixed dead time of approximately 0.1µs

to optimize the switching performance and prevent

overlap between the transistor module signals.

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Adnan Muhammed Ali Hakki,

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E-ISSN: 2415-1513

Volume 15, 2024

4 Conclusion

This paper presented an experimental investigation

of a welding machine operating in GMAW with a

focus on the spray transfer mode. Spray transfer

offers greater productivity compared to globular and

short-circuiting transfers, as it utilizes higher

currents and wire feed rates, resulting in increased

deposition rates. In spray transfer mode, the process

produced minimal spatter, excellent wash,

consistent deposition, and an aesthetically pleasing

bead appearance. However, spray transfer also

comes with some limitations, such as a very hot arc,

restricted usability to flat and horizontal positions,

limited penetration, and challenges when welding

thin materials. Minor defects, such as improper

fusion, were also observed in certain cases.

The droplet size was significantly smaller than

the wire diameter, and a shielding gas mixture of

95% argon and 5% oxygen was used to protect the

weld from oxidation. The welding machine

demonstrated three key operating points in spray

mode: 150A at a 10µs pulse width, 200A at a 13µs

pulse width, and 250A at a 17µs pulse width. These

results highlight the effectiveness and challenges of

using spray transfer mode in high-productivity

welding applications.

Declaration of Generative AI and AI-assisted

Technologies in the Writing Process

During the preparation of this work the authors used

ChatGPT in order to check grammar and spelling.

After using this tool/service, the authors reviewed

and edited the content as needed and take full

responsibility for the content of the publication.

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Contribution of Individual Authors to the

Creation of a Scientific Article (Ghostwriting

Policy)

The authors equally contributed to the present

research, at all stages from the formulation of the

problem to the final findings and solution.

Sources of Funding for Research Presented in a

Scientific Article or Scientific Article Itself

No funding was received for conducting this study.

Conflict of Interest

The authors have no conflicts of interest to declare.

Creative Commons Attribution License 4.0

(Attribution 4.0 International, CC BY 4.0)

This article is published under the terms of the

Creative Commons Attribution License 4.0

https://creativecommons.org/licenses/by/4.0/deed.en

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APPENDIX

Fig. 1: Welding machine block diagram

Fig. 2: Welding schematic circuit

Fig. 3: Equivalent circuit

Fig. 4: Electric discharge regimes

220V, 50Hz

Rectifier

(Full bridge) Filter

(Low pass)

Inverter

(Full bridge) Load

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Fig. 5: Spry GMAW drop transfer mode

Fig. 6: Electric discharge, Thermal arc

Fig. 7: Output Current at a 10µs PWM

Fig. 8: Frequency response curve of the welding current

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Table 1. Technical parameters of the module MG12200D-BA1MM

The presence of a built-in diode

YES

Maximum Collector-Emitter Voltage, V

1200

Maximum DC current of the collector at 25°C, A

300

Maximum Gate-Emitter Voltage, V

Maximum Gate-Emitter Threshold Voltage, V

Collector-Emitter Saturation Voltage, V

1.8

Maximum Collector Power Dissipation, W

1400

Rise time (tr), nS

Maximum junction temperature (Tj), °C

+150

Collector capacity, pF

1040

Table 2. Technical parameters of the Spry GMAW

CLK

(kHz)

Power Transfer Time

(uS)

(A)

Shielding Gas

Gas flow

(l/min)

CTWD

(mm)

Electrode

Type

Wire

Diameter

(inch)

150

95% Ar

5% O2

ER70S

0.035

200

95% Ar

5% O2

ER70S

0.045

250

95% Ar

5% O2

ER70S

0.062

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