Cold laps are defined as micro-lack of fusion defects at the weld toe more or less parallel to the surface of the parent plate. These defects are known to negatively influence the fatigue properties of weldments. Previous studies suggest that cold lap formation can not be avoided completely in Gas Metal Arc Welding (GMAW). Therefore, a better understanding of formation mechanisms is imperative to be able to minimize the number and size of these defects. The main objective of this work has been to provide a more comprehensive understanding of cold laps, including categorising, characterisation and defining the most significant factors for formation. GMAW was used to produce welds that were investigated by metallographic methods using light optical microscopy, scanning electron microscopy and energy dispersive spectrometry. A novel classification of cold laps was introduced and three types of cold laps were identified: spatter cold laps, overlap cold laps and spatter-overlap cold laps. It was shown that cold laps are partially or fully filled by oxides. The most common oxides are manganese silicon oxides which were concluded to be formed primarily by oxidation of droplets. The presence of oxides was found to significantly increase the tendency to form spatter cold laps as well as overlap cold laps. Particularly for overlap cold laps, it was found that the depth (in transverse direction of weld) is reduced when welding in a non-oxidising environment. Welding on blasted surfaces increased the cold lap formation by entrapment of gas. The droplet and base metal temperatures were also found to be significant factors in cold lap formation. For overlap cold laps the occurrence frequency decreased with increased preheating temperature of the base metal. Mechanisms of overflowing resulting in overlap cold laps were discussed based on an extensive literature review. Several phenomena are believed to contribute to overflow including Rayleigh instability, the balance of forces, transfer of lateral momentum by droplets and an outward Marangoni fluid flow of the weld pool. The present studies suggest that cold lap formation can be suppressed by ensuring that the welding process (arc) is as stable as possible and by welding on a preheated work piece in a non-oxidising environment.

CoordenaÃÃo de AperfeiÃoamento de Pessoal de NÃvel Superior / Este trabalho teve como objetivo o estudo exploratÃrio do processo MIG/MAG-DA-PI utilizando corrente alternada. Os ensaios foram executados em simples deposiÃÃo na posiÃÃo plana em chapas de aÃo baixo carbono com espessura de 3 mm utilizando arame eletrodo de 1,2 mm de diÃmetro. Foram realizados estudos sobre o nÃvel de corrente, tipo de onda aplicado em corrente alternada (CA-CP e CA-CC), a porcentagem de corrente alternada com o eletrodo na polaridade negativa (% CAEN), o sentido de deslocamento do eletrodo em relaÃÃo ao tipo de onda. Foi realizado tambÃm um estudo comparativo entre as soldagens realizadas em corrente alternada com corrente pulsada e sobre a disposiÃÃo dos eletrodos em relaÃÃo à direÃÃo de soldagem (âtandemâ e lado a lado). Foram avaliados os efeitos destes estudos nas caracterÃsticas geomÃtricas (penetraÃÃo, reforÃo e largura), na diluiÃÃo, na taxa de fusÃo do arame eletrodo, no aspecto superficial do cordÃo de solda e na microestrutura resultante na regiÃo de grÃos grossos da zona afetada pelo calor. Foi constatado que o aumento no nÃvel de corrente promove o aumento nas caracterÃsticas geomÃtricas, da diluiÃÃo e da taxa de fusÃo. A aplicaÃÃo de corrente alternada na soldagem MIG/MAG-DA-PI promoveu o aumento da taxa de fusÃo do arame, do reforÃo com a diminuiÃÃo da diluiÃÃo e da largura do cordÃo de solda. O aumento da % CAEN resultou no aumento do reforÃo, da taxa de fusÃo do arame, reduÃÃo da largura, da diluiÃÃo da solda e no refino da microestrutura. A aplicaÃÃo de corrente alternada no eletrodo anterior promoveu a reduÃÃo da diluiÃÃo com o aumento do reforÃo. Em comparaÃÃo com o uso da corrente pulsada, aplicaÃÃo de corrente alternada no processo MIG/MAG-DA-PI, para um mesmo nÃvel de corrente eficaz, resultou no aumento do reforÃo, da taxa de fusÃo do arame com a diminuiÃÃo da largura e da diluiÃÃo da solda. / The use of alternating current (or variable polarity) on the tandem GMAW process was investigated experimentally. Bead-on-plate test, in flat position, were carried out using a 1.2 mm diameter on mild steel sheet (3mm-thick). The level of welding current, waveform type applied in alternating current tandem GMAW: alternating-continuous current (AC-CC) and alternating-pulsed current (AC-PC), the percentage of alternating current in the negative polarity (% DCEN), the displacement direction of electrode applied related to waveform type. It was also carried out a comparative study between variable polarity and pulsed current in tandem GMAW and, a comparative study about the arrangement of electrodes in respect to the welding direction (tandem and side-by-side). The effects on welding geometric characteristics (penetration, reinforcement and width), weld dilution, electrode fusion rate and microstructure on coarsened grain heat affected zone (CG-HAZ) were evaluated. The experiments revealed that as current level increase, the geometrics characteristics, dilution and electrode fusion rate increased accordingly. The application of variable polarity in tandem GMAW process resulted in an increase on electrode fusion rate, reinforcement and, reduction of dilution and width of weld bead. Increasing % DCEN resulted in increase reinforcement and electrode fusion rate, reduction of dilution and width and, a refinement of microstructure. By applying variable polarity waveform on the trailing electrode, dilution is reduced and reinforcement is increased. Comparing welds made with pulsed current, the use of variable polarity in tandem GMAW process resulted in increase of reinforcement, electrode fusion rate and, reduction of width and dilution.