GMAW (Gas Metal Arc Welding) is one of the most important arc welding processes being adopted in modern manufacturing industry due to its advantages in productivity, energy efficiency and automation. By monitoring and improving some of the important properties of GMAW such as production rate, metal transfer and base metal heat input, researchers could bring the process efficiency and stability to a new level. In recent years, some innovative modifications of GMAW such as Twins, Tandem and laser-MIG hybrid welding have been adopted into many industrial applications for better productivity. In this dissertation, a novel GMAW called DB-GMAW (Dual Bypass Gas Metal Arc Welding) using two GTAW torches and one GMAW torch to construct a welding system, is proposed and developed. In DB-GMAW, two GTAW torches perform the bypass system which decouples the total welding current into base metal current and bypass current after the melt down of filler wire. Compared to conventional GMAW, DB-GMAW has many advantages in droplet formation, base metal heat input and penetration achievement due to its unique characteristics in welding arc and current flow. In the first place of the research, experimental system of DB-GMAW is constructed. Then, sufficient experiments under different parameters are performed to provide us a good understanding of the behaviors and characteristics of this novel GMAW process. Observation about metal transfer formation and base metal heat input is studied to verify its theoretical analysis. Full penetration of work piece via DB-GMAW is achieved based on a series of parameter testing experiments. Moreover, image processing techniques are applied to DB-GMAW to monitor the welding process and construct a feedback system for control. Considering the importance of maintaining stable full penetration during many welding applications, a nonlinear model of DB-GMAW full penetration is developed in this dissertation. To do that, we use machine vision techniques to monitor the welding profile of the work piece. A control algorithm based on the nonlinear model using adaptive control technique is also designed. The achievement of this dissertation provides a fundamental knowledge of a novel welding process: DB-GMAW, and a good guidance for further studies about DBGMAW.

This thesis work is carried out in Cargotec Sweden AB, Bromma Conquip to study the behavior of load carrying welded joints in different weld metal strength mismatch conditions and various penetration ratios. Static and fatigue strength calculations have been made using FEA and experimentation. The joint in the Telescopic beam of the spreader STS45 has been analyzed. Telescopic beam is one of the critical and main parts in the spreader, which is directly subjected to the load of containers at various ports. Previous studies show that this joint limits the strength of the spreader, it has thus been analyzed. To check the effect of different strength mismatch conditions in the weld metal, static strength calculations have been carried out. The effect of different penetration ratios on static and fatigue strength has also been studied. A cruciform test specimen is designed according to the joint configuration and the capacity of testing machine. Criteria for the selection of consumables has also been developed and following standards: Eurocode 3, AWS D1.1 and BSK07, have been compared for static joint design. Sub modelling, effective notch stress and beam theory techniques have been used to study the effect of weld metal penetration and size of weld throat on the fatigue strength of the welded joint in the Telescopic beam. The study show that matching or slight under matching in the filler material along with full penetration increases the ultimate strength capacity as well as the ductility in the joint. Results of Eurocode 3, AWS D1.1 and BSK 07 are close to each other. Apart from strength mismatch and penetration ratios, it is observed that the weld geometry and joint preparation has also effect on the strength of the joint. Fatigue analysis of the weld in the Telescopic beam using 3D Finite element analysis show that effective notch concept is not applicable to this part of the spreader.