A novel DE-GMAW method to weld steel tubes on simplified condition

A novel double-electrode gas metal arc welding method to weld steel tubes was investigated in this paper. The new method combines two welding torches and current sensors with welding position and angel design. In addition, a new control system was designed to improve the quality of welding seams. Experiments showed that different positions of main torch and bypass torch had different influence on welding quality. With bypass arc voltage at 35 V and suitable main welding feeder speed (WFS) at 10.2 m/min (400 in/min, 195 A), double arcs were ignited well and metal transfer was in spray mode. When the bypass WFS was at 8.9 m/min (350 in/min, 195 amps), welding seam formation and welding seam penetration were good. High-speed photos had been provided to prove the experimental results.