A novel Low-energy input welding system for lightweight material

Compared with other metal materials, the welding performance of lightweight materials is obviously lower, which seriously hinders the industrial application of such materials. In order to improve the welding effect of lightweight materials, the overall design scheme of cold welding power source (low energy input gas metal arc welding inverter power source) was designed. The proposed scheme adopts a bipolar soft switch control system on the of voltage and current waveforms for the hardware, to effectively reduce the switching energy consumption. Besides, A welding expert system is designed for the software. The expert system adopts a Newton interpolation welding parameter self-adjusting algorithm to realize fine adjustment of output control, which can not only eliminate splash factors, but also significantly reduce arc energy consumption. The Welding experiment results show that the welding process is stable and the weld joint is well formed. That’s to say, the cold welding power source based on the expert system is effective in welding lightweight materials, such as aluminum and magnesium sheets.