Model-based description of arc length as a synergetic system parameter in pulsed GMAW

Gas metal arc welding demonstrates a dynamic and inherently stochastic process behavior. Interdependencies of machine setup and process boundary conditions and the resulting process and weld product qualities are complex in nature, as the optimization of GMAW processes with regard to product quality demands expert knowledge. This work introduces a practical approach of mapping the arc length as a physical key process variable to the most influential pulsed GMAW setup parameters by means of generation and application of statistical process models. It further describes the necessary steps, including the determination of certain investigated variables, generating a statistical reasonable design of experiment and the actual model calculation and evaluation. Furthermore, field test evaluations of derived statistical models have been discussed, proving a successful statistical model generation process.