Control method and device for constant arc length welding of 1.6mm diameter aluminum alloy welding wire

Abstract

This invention provides a control method and apparatus for constant arc length welding of 1.6mm diameter aluminum alloy welding wire, relating to the field of aluminum alloy welding technology. The control method for constant arc length welding of 1.6mm diameter aluminum alloy welding wire is applied to a consumable electrode welding method, comprising multiple consecutive welding cycles. Each welding cycle includes a pulse welding period and an arc circuit detection period following the pulse welding period. The arc circuit detection period includes a wire forward feed period, a first arc detection period, a second arc detection period, and a wire retraction period. Through the synergistic effect of multi-stage speed control and current regulation, the pulse arc length is precisely maintained during the wire retraction period, achieving controllability of the droplet transfer process and arc length stability. This effectively solves the problems of arc drift, wire sticking, and poor weld bead formation in existing technologies, enabling precise control of the arc length and reducing wire sticking, thereby improving welding stability.

Description

Technical Field

[0001] This invention relates to the field of aluminum alloy welding technology, and more specifically, to a method and apparatus for controlling constant arc length welding of aluminum alloy welding wire with a diameter of 1.6 mm. Background Technology

[0002] Metal Inert Gas Welding (MIG) technology for aluminum alloys has significant application value in the aerospace, rail vehicle, and new energy vehicle manufacturing fields. This technology uses the workpiece as the positive electrode and the welding wire as the negative electrode, achieving efficient welding through a DC arc in a protective gas environment. While 1.2mm diameter welding wire is widely used in aluminum alloy welding, 1.6mm diameter welding wire exhibits significant advantages in welding 2-6mm thick aluminum alloys, including faster welding speed, lower heat input, and greater penetration, making it particularly suitable for welding components such as battery boxes in new energy vehicles. However, 1.6mm aluminum welding wire faces several technical challenges in practical applications: its high rigidity leads to unstable wire feeding, and its low resistance results in insufficient heating capacity during short circuits, easily causing abnormal wire sticking. Simultaneously, arc length control is difficult; too short an arc length can easily lead to wire sticking, while too long an arc length can cause undercut defects or burn out the contact tip. Summary of the Invention

[0003] The present invention aims to solve the problems of abnormal wire sticking and difficulty in controlling the arc length when welding 1.6mm diameter aluminum welding wire.

[0004] To address the aforementioned problems, this invention provides a method and apparatus for controlling constant arc length welding of 1.6mm diameter aluminum alloy welding wire.

[0005] In a first aspect, the present invention provides a control method for constant arc length welding of aluminum alloy welding wire with a diameter of 1.6mm, which is applied to a consumable electrode welding method, including multiple consecutive welding cycles, each welding cycle including a pulse welding period and an arc circuit detection period formed after the pulse welding period;

[0006] Arc circuit detection includes:

[0007] During the forward feeding phase of the welding wire, the welding wire is fed forward at a first constant speed. Under the welding current, the welding wire forms a molten droplet, and the molten droplet forms a necking. The first constant speed is greater than 0.

[0008] During the first arc detection period, the welding current is reduced to the droplet separation current, and the welding wire is fed forward at a second constant speed to make the droplet contact the molten pool and form a short circuit. At this time, the welding current cannot melt the welding wire, wherein the second constant speed is greater than the first constant speed.

[0009] During the second arc detection period, the welding wire is fed forward at a third constant speed, and the welding wire and the molten pool are kept in a short circuit state. At the same time, the short circuit contact time is set; where 0 ≤ third constant speed < first constant speed.

[0010] During the wire retraction period, the wire is retracted at a fourth constant speed to separate the wire from the molten pool. At the time of separation, the welding current is set to be maintained at the droplet separation current. The wire retraction time is set when the wire separates from the molten pool to control the wire to maintain a constant pulse arc length. The fourth constant speed is less than 0, and the absolute value of the third constant speed is less than the absolute value of the fourth constant speed.

[0011] Optionally, constant current control is used during the second arc detection period, and the welding current is maintained at the droplet separation current.

[0012] Alternatively, pulse welding is achieved by periodically alternating peak current and base current, with the droplet separation current set to 40% to 60% of the peak current.

[0013] Optionally, the pulse heat input to the aluminum alloy welding wire base material is reduced during the arc circuit detection period. The pulse heat is controlled by controlling the duration of the arc circuit detection period, thereby controlling the formation of molten droplets in the welding wire. The duration of the arc circuit detection period is negatively correlated with the pulse heat.

[0014] Optionally, during the wire retraction period, the duration of the wire retraction period is positively correlated with the fourth constant speed.

[0015] Optionally, during the wire retraction period, the smaller the fourth constant speed, the shorter the duration of the wire retraction period, resulting in a shorter pulse arc length of the wire.

[0016] Optionally, the welding method is dual-pulse welding, and the energy cycle of dual-pulse welding consists of a high-energy cycle and a low-energy cycle, with the time ratio of the high-energy cycle to the low-energy cycle being 9:1 to 25:1.

[0017] Optionally, multiple arc detection cycles and pulse combinations are used within the low-energy cycle, with the ratio of arc detection cycles to pulse combinations being 3:1 to 5:1.

[0018] Secondly, the present invention provides a control device for constant arc length welding of 1.6mm diameter aluminum alloy welding wire, used to operate and realize the control method for constant arc length welding of 1.6mm diameter aluminum alloy welding wire as described above. The control device includes a welding control circuit and a servo motor controlling the wire drawing welding gun respectively connected to the electrode.

[0019] The welding control circuit is used to provide welding current to the electrodes in each welding cycle;

[0020] The servo motor controls the wire drawing welding torch to control the feed speed and feed direction of the welding wire;

[0021] Electrodes are used to apply current to the welding area through welding wire.

[0022] Optionally, the welding control circuit includes:

[0023] The pulse welding current output module is used to output a pre-set peak current, base current, pulse duty cycle, and pulse frequency to the electrode during pulse welding to achieve stable, pulse-by-pulse welding; and

[0024] The arc circuit detection current output module is used to monitor the backflow current of the welding wire pulse arc to ensure welding stability, and to output current to the electrode during arc circuit detection.

[0025] The beneficial effects of the control method and apparatus for constant arc length welding of 1.6mm diameter aluminum alloy welding wire of the present invention are as follows: Each welding cycle includes a pulse welding period and an arc circuit detection period formed after the pulse welding period. During the arc circuit detection period, the welding wire is continuously fed at a first speed during the forward feed period, and the welding wire forms a molten droplet. After the molten droplet forms a necking structure, the first arc detection period begins, the welding current rapidly decreases to the droplet separation current, and the wire is fed to a second speed. The welding wire feeds the molten droplet forward until it contacts the molten pool, forming a short circuit. The combination of the forced short circuit stage and the droplet separation current effectively reduces the probability of wire sticking, while gradient speed control ensures the formation and controllable separation of the droplet necking. Subsequently, the second arc detection period begins, the forward feed speed of the welding wire is reduced, and the molten droplet... The droplet and molten pool are maintained in a short-circuit state while the short-circuit contact time is set to ensure sufficient droplet transition and stabilize the molten pool temperature. Then, during the wire retraction period, the droplet separation current is maintained, and the wire is retracted to controllably separate from the droplet. During separation, the wire retraction time is set to maintain a constant pulse arc length, preventing burnt-out of the welding tip. The reverse movement during the wire retraction period suppresses molten pool disturbance and reduces spatter. Through the synergistic effect of multi-stage speed control and current regulation, the pulse arc length is precisely maintained during the wire retraction period, achieving controllability of the droplet transition process and arc length stability. This effectively solves the problems of arc drift, wire sticking, and poor weld bead formation in existing technologies, enabling precise control of the arc length and reducing wire sticking, thereby improving welding stability. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the waveforms of wire feed speed, welding current, and welding voltage during one welding cycle of the constant arc length welding control method for 1.6mm diameter aluminum alloy welding wire according to an embodiment of the present invention.

[0027] Figure 2 This is a schematic diagram of the control device for constant arc length welding of 1.6mm diameter aluminum alloy welding wire according to an embodiment of the present invention;

[0028] Figure 3 This is a waveform diagram illustrating the arc height adjustment frequency for high and low energy cycles and the control of heat by increasing the number of detection cycles in Example 1. Detailed Implementation

[0029] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Although some embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the present invention. It should be understood that the accompanying drawings and embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of protection of the present invention.

[0030] Unless otherwise defined, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this invention's description is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0031] The term "comprising" and its variations as used herein are open-ended, meaning "including but not limited to"; the term "based on" means "at least partially based on"; the term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments"; and the term "optionally" means "optional embodiments". Definitions of other terms will be given in the following description. It should be noted that the concepts of "first," "second," etc., mentioned in this invention are used to distinguish different objects, not to describe a specific order or hierarchy. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0032] In related technologies, aluminum alloy MIG welding technology is widely used in many manufacturing fields. However, when using 1.6mm diameter welding wire, problems such as unstable wire feed speed and rapid cooling of the molten pool due to low resistance exist, which can easily lead to defects such as arc length drift, wire sticking, spatter, and burnt contact tip. Although traditional dual-pulse welding controls heat by switching between high and low pulses, there are still problems with excessive heat input and unstable arc length during the low pulse phase, resulting in unclear weld transition and obvious arc drift.

[0033] To address the problems existing in the aforementioned related technologies, this embodiment provides a method and apparatus for controlling constant arc length welding of 1.6mm diameter aluminum alloy welding wire.

[0034] like Figure 1 As shown, the present invention provides a control method for constant arc length welding of 1.6mm diameter aluminum alloy welding wire, which is applied to a consumable electrode welding method. It includes multiple consecutive welding cycles, each welding cycle (Pc) including a pulse welding period and an arc circuit detection period (Ts) formed after the pulse welding period (Tp).

[0035] The arc circuit detection period (Ts) includes:

[0036] During the wire forward feed period (Tb), the wire is fed forward at a first constant speed. The wire forms a molten droplet under the welding current, and the molten droplet forms a necking. The first constant speed is greater than 0.

[0037] During the first arc detection period (Ts1), the welding current is reduced to the droplet separation current (Isr), and the welding wire is fed forward at a second constant speed to bring the droplet into contact with the molten pool and form a short circuit. At this time, the welding current cannot melt the welding wire, wherein the second constant speed is greater than the first constant speed.

[0038] During the second arc detection period (Ts2), the welding wire is fed forward at a third constant speed, and a short circuit is maintained between the welding wire and the molten pool. The short circuit contact time is set at the same time; where 0 ≤ third constant speed < first constant speed.

[0039] During the wire retraction period (Ts3), the wire is retracted at a fourth constant speed to separate the wire from the molten pool. At the time of separation, the welding current is set to be maintained at the droplet separation current. The retraction time of the wire is set when the wire separates from the molten pool, and the wire is controlled to maintain a constant pulse arc length. The fourth constant speed is less than 0, and the absolute value of the third constant speed is less than the absolute value of the fourth constant speed.

[0040] Specifically, the first constant speed refers to the uniform wire feeding speed during the forward feed phase, which can be achieved using servo motor control. Its function is to form stable droplets and promote necking under pulsed current. A first constant speed > 0 means that the forward feed direction of the welding wire is defined as positive. The second constant speed refers to the wire feeding speed during the first arc detection phase, which is greater than the first constant speed. This can be achieved by increasing the motor drive frequency, and is used to push the droplets to contact the molten pool to form a reliable short circuit. The third constant speed refers to the wire feeding speed during the second arc detection phase, which is less than the first constant speed. This can be achieved by reducing the motor speed, and is used to maintain the short-circuit contact time to ensure sufficient droplet transition. The fourth constant speed refers to the speed at which the welding wire is withdrawn in the reverse direction during the retraction phase. This can be achieved by reversing the motor, and its function is to prevent molten pool adhesion through rapid separation. A fourth constant speed < 0 means that the reverse withdrawal direction of the welding wire is defined as negative. The droplet separation current refers to the current value below the welding wire melting threshold, specifically in the range of 40%-60% of the peak current (Ipp). It is output through the constant current module of the welding power supply and is used to suppress arc reignition during the short-circuit phase.

[0041] In this embodiment, each welding cycle includes a pulse welding period and an arc circuit detection period formed after the pulse welding period. The core function of the pulse welding period is to accurately control the droplet transfer and arc energy to ensure the stability of the welding process. The pulse welding period is the main working stage in each welding cycle, accounting for 50%-80% of the total. The pulse period includes two sub-stages: "peak current (heating)" and "base current (cooling)". The base current can reduce the average heat input of the weld and prevent the aluminum alloy from deforming or becoming grainy due to overheating. In one welding cycle, the pulse welding period is entered first, followed by the arc circuit detection period, and then the cycle repeats to the pulse welding period and arc circuit detection period of the next cycle, forming a continuous welding process. During the arc circuit detection period, the wire is continuously fed at a first constant speed during the forward feed phase, and a molten droplet forms. Once the droplet forms a necking structure, the first arc detection phase begins. The welding current rapidly decreases to the droplet separation current, and the wire is fed at a second constant speed. The wire is fed forward until the droplet contacts the molten pool, forming a short circuit. The combination of the forced short circuit phase and the droplet separation current effectively reduces the probability of wire sticking, while gradient speed control ensures the formation and controllable separation of the droplet necking. Subsequently, the second arc detection phase begins, and the wire feed speed is reduced. The droplet and molten pool maintain a short circuit while the short circuit contact time is set to ensure sufficient droplet transition and stabilize the molten pool temperature. The process begins with the wire retraction phase, maintaining the droplet separation current. The wire retracts to controllably separate from the droplet. During separation, the wire retraction time is set to maintain a constant pulse arc length, preventing burnt-out of the welding tip. The reverse motion during the wire retraction phase suppresses molten pool disturbance and reduces spatter. Through the synergistic effect of multi-stage speed control and current regulation, the pulse arc length is precisely maintained during the wire retraction phase, achieving controllability of the droplet transfer process and arc length stability. This effectively solves the problems of arc drift, wire sticking, and poor weld bead formation in existing technologies, enabling precise control of arc length and reducing wire sticking, thereby improving welding stability.

[0042] Specifically, when the welding wire contacts the molten pool and forms a short circuit (i.e., enters the second arc detection period Ts2), constant current control is adopted, meaning that the output current set for both the second arc detection period Ts2 and the welding wire retraction period Ts3 is Is. At this time, during the welding wire retraction period Ts3, affected by the welding wire retraction speed, the welding current will decrease from the set output current Is to the droplet separation current Isr.

[0043] Optionally, constant current control is used during the second arc detection period, and the welding current is maintained at the droplet separation current.

[0044] Specifically, constant current control refers to adjusting the output current of the welding power supply through closed-loop feedback to maintain a constant value. This can be achieved by using a current sensor to collect the loop current signal in real time and adjusting the power supply output voltage through a proportional-integral controller. Droplet separation current refers to the minimum current value required to maintain the necking and fracture of the liquid metal between the droplet and the welding wire. This can be calculated using a preset current threshold or a mathematical model based on the welding wire material and diameter.

[0045] In this optional embodiment, the welding current is stabilized at the droplet separation current level by a constant current control module. At this point, the welding wire and the molten pool maintain a short-circuit contact. The necking of the liquid metal is subjected to Joule heating generated by the constant current, causing the necking diameter to gradually decrease until it breaks. Because the current value is strictly limited to a range insufficient to melt the welding wire body, irregular droplet separation caused by a sudden rise in molten pool temperature is avoided. This control method makes the breakage process of the liquid metal necking predictable, ensuring the consistency of droplet transition morphology each time. The constant current mode eliminates the influence of current fluctuations on the droplet separation process, allowing the breakage process of the liquid metal necking to be completely controlled by the preset current value and wire feed speed. It can precisely control the contact time between the droplet and the molten pool, avoiding abnormal changes in molten pool heat caused by current fluctuations. The droplet separation process is completed smoothly under the action of a constant current, effectively preventing wire sticking defects caused by excessively rapid cooling of the molten pool, while maintaining the stability of the arc length and solving the problem of arc drift during the short-circuit stage.

[0046] Alternatively, pulse welding is achieved by periodically alternating peak current (Ipp) and base current (Ipb), with the droplet separation current set to 40% to 60% of the peak current.

[0047] Specifically, the periodically alternating peak current (Ipp) and base current (Ipb) refer to the periodic switching between high and low current welding modes during the welding process. The peak current is used to form droplets at the tip of the welding wire and promote droplet necking, while the base current is used to maintain arc stability and control the heat of the molten pool. The current switching can be achieved by adjusting the pulse frequency and duty cycle. A droplet separation current (Isr) of 40% to 60% of the peak current means that after detecting droplet necking, the welding current is reduced to a specific percentage range of the peak current. This percentage range provides sufficient energy to separate the droplet from the welding wire while avoiding excessive current that could lead to overheating or spattering of the molten pool. For example, the current output can be adjusted in real time via a current feedback module during arc loop detection. Preferably, the droplet separation current is set to 50% of the peak current.

[0048] In this optional embodiment, during the pulse welding stage, the peak current and base current alternate to form a dynamic heat input environment. The peak current stage promotes rapid droplet formation and necking, while the base current stage maintains arc stability and dissipates heat from the molten pool. When entering the arc circuit detection period, the welding current is switched to the droplet separation current, which is set to 40% to 60% of the peak current. This ensures that the droplets receive sufficient heat at the necking point to complete separation, while avoiding spatter caused by excessive current or incomplete droplet separation and adhesion to the wire tip due to insufficient current. By limiting this ratio range, the surface tension of the droplets and the current heat input are balanced, allowing the droplets to smoothly transition to the molten pool under short-circuit conditions, thereby maintaining a constant arc length. By dynamically linking the droplet separation current with the peak current, the energy input during the separation stage can be adaptively adjusted according to actual welding conditions, significantly improving the reliability and stability of droplet separation. This effectively solves the problems of wire sticking, spattering, and arc instability caused by improper current control during the droplet separation stage of 1.6 mm diameter aluminum alloy welding wire. To reduce welding defects while maintaining a constant arc length, and to avoid burning the contact tip or causing the molten pool to go out of control.

[0049] Optionally, the pulse heat input to the aluminum alloy welding wire base material is reduced during the arc circuit detection period. The pulse heat is controlled by controlling the duration of the arc circuit detection period, thereby controlling the formation of molten droplets in the welding wire. The duration of the arc circuit detection period is negatively correlated with the pulse heat.

[0050] Specifically, the arc loop detection period refers to the specific time interval used to detect the arc status after the pulse welding stage. This can be achieved by using a current sensor and a timing module working together. During this period, the droplet transition state is monitored and controlled by adjusting the wire feed speed and current parameters. Pulse heat refers to the total amount of heat energy input to the base material per unit time, which can be achieved by adjusting the welding current amplitude and duration. During the arc loop detection period, the heat input is reduced by decreasing the current amplitude. The negative correlation means that as the duration of the arc loop detection period increases, the heat input per unit time decreases. This can be achieved through a preset time-heat correspondence algorithm for dynamic matching. When the detection period is extended, the system automatically reduces the current output to maintain the total heat balance.

[0051] In this optional embodiment, during the arc circuit detection phase, extending the duration of this phase disperses the heat input to the base material per unit time, thereby reducing the instantaneous temperature peak in the molten pool region. This allows the molten droplets to complete the necking and separation process under lower heat input conditions. This dynamic adjustment mechanism improves the uniformity of droplet size while avoiding drastic fluctuations in the molten pool caused by localized overheating. In scenarios with a shortened detection period, the system maintains the necessary heat input by increasing the current output, ensuring a continuous and stable droplet transition process. By establishing a negative correlation between the detection period duration and heat, precise closed-loop control of the heat input is achieved. This solves the problem of molten pool instability caused by excessive heat during the droplet transition phase, making the droplet separation process more stable and controllable, and significantly reducing welding spatter and burn-through defects. Simultaneously, by dynamically matching the detection period duration and current parameters, it ensures that droplets of consistent size are formed under different welding conditions, improving weld surface quality and mechanical properties.

[0052] As described above, in a possible implementation, when the detection period is extended from 50 milliseconds to 80 milliseconds, the system reduces the welding current from 150 amperes to 100 amperes, allowing the droplet to complete the necking and separation process under lower heat input conditions. This dynamic adjustment mechanism improves droplet size uniformity while avoiding drastic fluctuations in the molten pool caused by localized overheating. In scenarios with a shortened detection period, the system maintains the necessary heat input by increasing the current output, ensuring a continuous and stable droplet transition process.

[0053] Optionally, during the wire retraction period, the duration of the wire retraction period is positively correlated with the fourth constant speed.

[0054] Specifically, the duration of the wire retraction period refers to the time range required for the wire to detach from the molten pool. This can be achieved by setting the retraction time parameter of the servo motor, which is related to the value of the fourth constant speed. The fourth constant speed refers to the rate of wire retraction, which can be achieved by adjusting the rotational speed parameter of the servo motor. This rate directly affects the efficiency and stability of the wire detaching from the molten pool.

[0055] In this optional embodiment, the positive correlation between the wire retraction period and the fourth constant speed is dynamically matched to achieve precise control of the wire detachment process. When the fourth constant speed increases, the retraction period lengthens synchronously, ensuring that the high-speed retraction action lasts long enough for the molten droplet to completely detach from the molten pool. When the fourth constant speed decreases, the retraction period length shortens accordingly, avoiding excessive contact time between the wire and the molten pool due to low-speed retraction. This parameter matching mechanism, through real-time adjustment of the synergistic effect of the retraction duration and speed, keeps the wire detachment process synchronized with the molten pool state, thereby maintaining a constant pulse arc length. By establishing a positive correlation between speed and duration, the retraction parameters are dynamically adjusted according to actual working conditions, solving the problem of molten pool disturbance caused by parameter mismatch. Stable separation of the wire and molten pool is achieved, effectively avoiding wire sticking, burnt contact tip, or molten pool spatter caused by mismatch between retraction speed and duration. Simultaneously, by dynamically maintaining a constant pulse arc length, the stability of the welding process and the quality of the weld formation are improved.

[0056] Optionally, during the wire retraction period, the smaller the fourth constant speed, the shorter the duration of the wire retraction period, resulting in a shorter pulse arc length of the wire.

[0057] Specifically, the fourth constant speed refers to the rate of the reverse movement of the welding wire when it leaves the molten pool. This can be achieved using a closed-loop speed control system that drives the welding torch pulling mechanism with a servo motor, matching the welding conditions by setting different speed levels. The retraction period duration refers to the duration of the reverse movement of the welding wire during its separation from the molten pool. This can be controlled by a current detection module monitoring the voltage change at the moment of droplet separation, triggering a timer. The pulse arc length refers to the distance between the welding wire tip and the molten pool surface when the arc reignites after the droplet detaches. This can be controlled by adjusting the product parameter of the retraction speed and the retraction time to manage the arc energy accumulation process.

[0058] In this optional embodiment, when the servo motor drives the welding wire to retract at a lower speed, the acceleration of the welding wire leaving the molten pool decreases, and the time window for balancing the surface tension and electromagnetic contraction force required for the droplet neck to break is shortened. At this time, a current sensor detects the short-circuit release signal in real time, triggering a timer to terminate the retraction action within a preset threshold. Because the reduced speed leads to a decrease in displacement per unit time, the retraction time needs to be shortened to achieve the same separation distance. This speed-time product constraint mechanism limits the initial length of the arc reignition to a controllable range. At the moment of droplet separation, the distance between the welding wire tip and the molten pool surface is determined by the linear relationship between the retraction speed and the duration, thereby avoiding the arc length drift caused by single parameter adjustment in traditional methods. Through the speed-time product constraint mechanism, a dual-parameter coupled control is formed in the droplet separation stage, effectively suppressing the arc overshoot phenomenon caused by high-speed retraction, while avoiding the risk of secondary short circuits that may be caused by low-speed retraction. It achieves precise control of the arc length during the process of the welding wire leaving the molten pool, effectively preventing the contact tip from burning due to excessive arc length caused by the inertia of retraction, and avoiding spatter caused by secondary short circuit of molten droplets due to insufficient retraction.

[0059] As mentioned above, in a possible implementation, the speed-time dynamic matching mechanism enables the pulse arc length to be stably maintained in the range of 0.8-1.2mm in thin plate welding, ensuring balanced heat input to the molten pool and improving weld formation consistency by more than 30%.

[0060] Optionally, the welding method is dual-pulse welding, and the energy cycle of dual-pulse welding consists of a high-energy cycle and a low-energy cycle, with the time ratio of the high-energy cycle to the low-energy cycle being 9:1 to 25:1.

[0061] Specifically, dual-pulse welding refers to a process that uses periodic switching of high and low intensity current waveforms to form a welding heat source. This can be achieved by superimposing high-frequency pulses with low-frequency modulation. The high-frequency pulses create high heat input conditions, while the low-frequency modulation regulates the cooling rate of the molten pool. The energy cycle refers to a complete cyclic unit in dual-pulse welding where high and low energy phases alternate. This can be achieved by setting the pulse frequency and duty cycle parameters; the high-energy cycle corresponds to the duration of the high-intensity current, and the low-energy cycle corresponds to the duration of the low-intensity current. The time ratio refers to the proportion of the duration of the high-energy cycle to the low-energy cycle within a single energy cycle. This can be achieved by adjusting the pulse waveform parameters or the output timing of the control circuit. This ratio range is used to balance the molten pool formation rate and cooling efficiency.

[0062] In this optional embodiment, a high-intensity pulsed current is used during the high-energy cycle to achieve rapid droplet transfer and weld pool formation, while the current intensity is reduced during the low-energy cycle to decrease heat input. By controlling the time ratio of the high-energy cycle to the low-energy cycle within the range of 9:1 to 25:1, the high-energy phase dominates, effectively shortening the duration of the low-energy phase. This time ratio limits the heat accumulation caused by the lag in wire feed speed adjustment during the high-low energy switching process to a controllable range, thereby avoiding arc drift caused by overheating of the weld pool. Simultaneously, the longer duration of the high-energy cycle ensures sufficient thermal stability of the weld pool, maintaining stable liquid metal flow even in the low-energy phase, forming a clearly defined scaly weld bead pattern. By optimizing the time ratio of the high-energy cycle, the necessary weld pool cooling process is preserved while avoiding abnormal weld pool solidification caused by a sudden drop in heat. Dynamic heat balance is achieved through time ratio adjustment, improving weld bead morphology while maintaining arc stability. This effectively suppresses heat accumulation in the weld pool caused by excessively long low-energy phases during dual-pulse welding, solving the problems of arc drift and blurred weld bead transition. Optimizing the time ratio of high and low energy cycles allows the molten pool to fully form during the high-energy phase, followed by a brief maintenance period during the low-energy phase to complete cooling and shaping, resulting in a welded joint with clear scaly patterns. This control method significantly improves weld surface quality and process stability while ensuring welding efficiency.

[0063] Optionally, multiple arc detection cycles and pulse combinations are used within the low-energy cycle, with the ratio of arc detection cycles to pulse combinations being 3:1 to 5:1.

[0064] Specifically, the arc detection cycle refers to the detection phase where the wire feeding action is adjusted by monitoring the droplet separation state and changes in arc length. This can be achieved using a current sensor and servo motor linkage control to correct the wire feeding speed in real time to maintain a constant arc length. The pulse combination refers to the periodic current output phase required to maintain molten pool stability during low-energy cycles. This can be achieved using a stepped-attenuation pulse current waveform to supplement minimum welding heat and prevent molten pool cooling. The 3:1 to 5:1 ratio range means that a pulse combination is executed once after every 3 to 5 arc detection cycles. This can be achieved by using a timing controller to adjust the alternation frequency of detection and pulses, balancing the synergy between arc stability monitoring and energy input.

[0065] In this optional embodiment, during the low-energy cycle of dual-pulse welding, the arc detection cycle is set to actively monitor the contact state between the molten droplet and the weld pool, and the molten droplet is separated in a timely manner by adjusting the wire retraction speed; the pulse combination is set to output a base current for a preset duration to maintain the fluidity of the weld pool. When the arc detection cycle and pulse combination are executed alternately in a ratio of 3:1 to 5:1, multiple molten droplet state monitoring and arc length corrections are completed within each low-energy cycle, while intermittent pulses supplement energy to prevent the weld pool from solidifying. This periodic alternation mechanism limits the arc drift amplitude to a controllable range, and the heat gradient in the weld bead scaly transition region is smoothed. By setting an independent timing ratio for the detection cycle and pulse combination, the arc stability control and weld pool heat management are decoupled, which reduces the heat input redundancy in the low-energy stage and compensates for wire feeding fluctuations caused by wire rigidity through high-frequency detection actions. It effectively suppresses arc drift during low-energy cycles, improves the clarity of the transition boundary between the scaled and non-scaled areas of the scaled weld bead, and reduces the probability of abnormal wire sticking through periodic droplet separation control, while also reducing the problem of contact tip burn-out caused by arc length fluctuations.

[0066] like Figure 2 As shown, the present invention provides a control device for constant arc length welding of 1.6mm diameter aluminum alloy welding wire, which is used to operate and realize the control method for constant arc length welding of 1.6mm diameter aluminum alloy welding wire as described above. The control device includes a welding control circuit and a servo motor controlling the wire drawing welding gun respectively connected to the electrode.

[0067] The welding control circuit is used to provide welding current to the electrodes in each welding cycle;

[0068] The servo motor controls the wire drawing welding torch to control the feed speed and feed direction of the welding wire;

[0069] Electrodes are used to apply current to the welding area through welding wire.

[0070] Specifically, the welding control circuit refers to a circuit module capable of outputting periodically varying welding current. It can be implemented using a combination of a digital signal processor and power semiconductor devices, controlling the current output through preset pulse waveform parameters. The servo motor-controlled wire-feeding torch refers to a drive mechanism with bidirectional wire feeding capabilities. This can be implemented using a closed-loop controlled servo motor and ball screw transmission structure, adjusting the wire movement parameters through real-time feedback. The electrode is a conductive component that conducts current to the welding area. It can be a conductive tip structure made of copper alloy with a conductive barrier layer, fixing the welding wire using mechanical clamping.

[0071] In this embodiment, the welding control circuit outputs a composite current waveform encompassing both the pulse welding period and the arc loop detection period within each welding cycle. During pulse welding, droplet transfer is achieved through alternating peak and base currents. During arc loop detection, the current is reduced to the droplet separation level and maintained constant to detect short circuits. A servo motor controls the wire-drawing welding torch to dynamically adjust the wire feeding direction and speed according to the welding stage. During pulse welding, the wire is fed forward at a first constant speed; during arc loop detection, the second and third constant speeds are switched sequentially for forward wire feeding; and during droplet separation, the wire is drawn backward at a fourth constant speed. During current conduction, the electrode reduces contact resistance through a conductive barrier layer, preventing abnormal heating between the welding wire and the contact tip. The coordinated operation of these three components ensures precise wire feeding control throughout the droplet formation, short circuit detection, and separation stages, forming a stable closed-loop arc length adjustment. By coordinating the bidirectional wire feeding of the servo motor with the welding current waveform, a reverse withdrawal action is immediately executed after the droplet contacts the molten pool, effectively eliminating the wire feeding delay problem caused by the high rigidity of the welding wire. Meanwhile, the welding control circuit maintains the droplet separation current during arc circuit detection to avoid spatter defects caused by overheating of the molten pool. It solves the arc drift problem caused by wire feed speed fluctuations in 1.6mm diameter aluminum alloy welding wire by precisely controlling the wire's motion parameters during the forward feed and reverse withdrawal stages, ensuring a stable and controllable droplet separation process. The timing matching of welding current and wire feed action effectively suppresses abnormal wire sticking during short-circuit contact, and the application of a conductive barrier layer reduces the probability of contact tip burnout. The closed-loop controlled servo wire feed system overcomes the fluctuations in wire feed resistance caused by the high rigidity of the welding wire, keeping the arc length constant throughout the welding process.

[0072] Optionally, such as Figure 2 As shown, the welding control circuit includes:

[0073] The pulse welding current output module is used to output a pre-set peak current, base current, pulse duty cycle, and pulse frequency to the electrode during pulse welding to achieve stable, pulse-by-pulse welding; and

[0074] The arc circuit detection current output module is used to monitor the backflow current of the welding wire pulse arc to ensure welding stability, and to output current to the electrode during arc circuit detection.

[0075] Specifically, the pulse welding current output module refers to a circuit unit capable of periodically switching between peak and base currents. This can be achieved using a dual closed-loop control circuit combined with an Insulated-Gate Bipolar Transistor (IGBT) power device, controlling the droplet transition process by adjusting the duty cycle and frequency parameters. The arc circuit detection current output module refers to a circuit unit with current monitoring and output adjustment functions. This can be achieved using a Hall sensor combined with a PID controller (Proportional-Integral-Derivative controller), detecting the return current signal in real time and adjusting the output value of the droplet separation current accordingly. "One pulse, one droplet" means that each complete current pulse corresponds to a droplet smoothly transitioning from the end of the welding wire into the molten pool, forming a "pulse-droplet" state. This is the ideal droplet transition state in pulsed MIG / MAG welding (gas metal arc welding) and is crucial for achieving stable welding.

[0076] The arc circuit detection current output module outputs welding current to the electrode during the wire forward feed period of the arc circuit detection, and during the first arc detection period, the second arc detection period and the wire retraction period of the arc circuit detection.

[0077] In this optional embodiment, during pulse welding, the alternating output of peak current and base current is periodically switched through a preset duty cycle parameter, ensuring that a single droplet transitions within each pulse cycle. The duration of the base current is set sufficient to maintain arc stability but insufficient to generate new droplets. During arc circuit detection, the droplet separation current is set to a constant current below the wire melting threshold. A Hall sensor collects current fluctuation signals in the arc circuit in real time, triggering wire retraction when the detected current exceeds a preset threshold. The collaborative operation of the two modules is achieved through a time-sharing control strategy. During pulse welding, the main circuit outputs a high-energy pulse, while during arc detection, the auxiliary circuit outputs a low-energy detection current, thus avoiding arc drift caused by high-low energy switching. By independently setting the detection current output module, the arc circuit status is continuously monitored and a specific separation current is output during the low-energy phase, ensuring precise synchronization between wire retraction and droplet separation, reducing molten pool disturbance caused by sudden current changes. This system achieves time-division independent control of pulse energy output and arc status detection during welding, solving the problem of wire feeding fluctuation caused by the high rigidity of 1.6mm diameter aluminum welding wire. Precise adjustment of pulse parameters ensures the stability of droplet transfer, real-time monitoring of the arc circuit effectively suppresses short-circuit wire sticking, and closed-loop control of the separation current avoids the sudden current change during droplet detachment in traditional methods.

[0078] As described above, in possible implementations, precise adjustment of pulse parameters ensures droplet transfer stability, real-time monitoring of the arc circuit effectively suppresses short-circuit wire sticking, and closed-loop control of the separation current avoids the sudden current change when the droplet detaches in traditional methods. Ultimately, the arc length fluctuation range is controlled within ±0.2mm, and the contact tip loss rate is reduced to less than 0.8 per kilometer of welding wire.

[0079] Example 1

[0080] like Figure 1 As shown, the welding cycle T begins at the start time Pst of the pulse welding period Tp. During the pulse welding cycle Tp, the welding current is pulsed with preset peak current Ipp, base current Ipb, pulse duty cycle, and pulse frequency, forming a high-heat welding input. In this process, the welding wire is fed forward at a constant rate, and the molten droplets are integrated into the molten pool at a rate of one droplet at a time, forming a scaly zone.

[0081] After the high-heat pulse welding period (Tp) ends, the arc detection period (Ts) begins. During Ts, the welding current continuously melts the welding wire. When half of the molten droplet has formed, the welding current is reduced to the droplet separation current (Isr), thus slowing down the droplet formation rate. The welding wire accelerates its forward feed until the droplet contacts the molten pool, then the feed speed is reduced or kept zero. The molten wire droplet enters the molten pool, and the base metal cools rapidly. The height of the welding wire relative to the base metal can be reset by checking the voltage droplet and molten pool detection. The low heat input during Ts and the high heat input during pulse welding (Tp) create a significant difference, resulting in a clearer transition between the scaly and non-scaly areas in the post-weld scaly weld bead. Afterwards, the molten droplet and the base material are kept in a short-circuit state while the short-circuit contact time is set to further extend the cooling of the base material and reduce the heat of the arc detection pulse; then the droplet separation current Isr is increased to accelerate the droplet entering the molten pool, and the welding wire is retracted to separate from the droplet. During separation, the welding wire retraction time is set to be maintained at the pulse arc length.

[0082] The arc detection period Ts comprises three stages: In the initial stage Tb, the welding wire is fed normally, and molten droplets form under the welding current. Once the droplets are formed and compressed, the arc detection stage Ts1 begins. The welding current is reduced to the droplet separation current Isr, and the forward feed speed of the welding wire is increased to a set forward feed speed value and maintained, so that the droplets contact the molten pool, forming a short circuit. The welding current does not melt the welding wire. Then, the arc detection stage Ts2 begins. In this embodiment, during arc detection stage Ts2, wire feeding is stopped; that is, the wire feed speed is zero or a very small set speed for slow forward feeding. This set speed is only used to maintain the short circuit between the welding wire and the base metal. The welding current does not melt the welding wire, and the short circuit between the welding wire and the molten pool is maintained. After the set cooling time is reached during the arc detection phase, the wire retraction phase Ts3 begins. The wire retraction speed is increased to the set retraction speed value and maintained to separate the wire from the base material. When the wire separates from the base material, the welding current is set to be maintained at a droplet separation current Isr.

[0083] In this embodiment, after the welding wire contacts the molten pool and forms a short circuit (i.e., enters the arc detection stage Ts2), constant current control is adopted, meaning that the output current set for both the cooling stage Ts2 and the retraction stage Ts3 is Is2. At this time, during the retraction stage Ts3, influenced by the welding wire retraction speed, the welding current will decrease from the set output current Is2 to the droplet separation current Isr. However, this embodiment does not impose any limitations on this. The user can determine the welding current for the non-melting welding wire during the initial stage Ts1 and the cooling stage Ts2 of the arc detection period based on parameters such as the welding wire material and diameter.

[0084] Since the heat input to the base material is significantly reduced during the arc detection period (Ts), the average heat input can be controlled by adjusting the duration of the arc detection period (Ts) within the welding cycle. A longer arc detection period (Ts) results in a smaller heat pulse and a smaller average heat input to the base material. Conversely, a shorter arc detection period (Ts) results in a larger heat pulse and a larger average heat input to the base material.

[0085] In existing scaly weld bead methods, precise control of multiple pulse parameters (such as peak current Ipp, base current Ipb, pulse duty cycle, and pulse frequency) and wire feed speed during pulse welding is required to control the arc length. Similarly, the heat input to the base material is also based on these multiple pulse parameters, and the control of arc length and heat input often contradict each other when adjusting specific parameters, making precise control difficult. However, in the arc welding control method provided in this embodiment, during the arc detection period Ts, the wire retraction causes the wire to detach from the base material. The retraction distance between the wire tip and the base material eliminates the influence of the pulse welding period on the arc length during that cycle, resetting the arc length for the next welding cycle. Therefore, controlling the wire retraction parameters during welding is sufficient to control the arc length for the subsequent welding cycle.

[0086] In this embodiment, when the arc detection period Ts enters the retraction stage Ts3, the retraction speed of the welding wire increases to the retraction speed set value Ws3 and remains thereafter. Under this retraction condition, since the retraction speed of the welding wire rapidly increases to the retraction speed set value Ws3, the parameters of the welding wire retraction are the retraction speed set value Ws3 and / or the retraction holding time. The arc length of the next cycle is adjusted by controlling these two parameters. Specifically, within the retraction stage Ts3, the larger the retraction speed set value, the longer the holding time of the retraction stage Ts3, and the longer the arc length will be; the smaller the retraction speed set value Ws3, the shorter the holding time of the retraction stage Ts3, and the shorter the arc length will be. However, this embodiment does not impose any limitations on this. In other embodiments, when the retraction speed of the welding wire gradually increases to the retraction speed set value at a certain rate, the parameters of the welding wire retraction are the retraction speed set value and / or the rate of change of the retraction speed.

[0087] In this arc welding control method, arc length control is based solely on the pre-set retraction parameters of the welding wire, completely independent of the pulse parameters within the pulse welding cycle Tp. This is a novel open-loop control method. This open-loop control method requires very few parameter adjustments for arc length control, making it extremely simple and highly accurate. Furthermore, since arc length control is completely independent of the pulse parameters within the pulse welding cycle Tp, the control of pulse parameters within Tp (i.e., the control of input heat) only needs to meet the requirement of one pulse at a time. Input heat control becomes simpler and more precise, completely solving the problem of precise arc length control. In addition, as mentioned earlier, the average input heat can be controlled by adjusting the length of Ts during arc detection, further separating the input heat control from the pulse welding cycle Tp, thereby further simplifying the control of pulse parameters within Tp during pulse welding.

[0088] In summary, in the arc welding control method provided in this embodiment, the adjustment of the pulse parameters during the pulse welding period Tp only needs to meet the requirement of one pulse per drop, while the control of the arc length and average input heat is achieved by adjusting the parameters during the arc detection period Ts. The pulse welding period Tp and the arc detection period Ts are two independent periods, and the adjustment of parameters in each period will not interfere with each other, making parameter control more convenient and more accurate. Furthermore, in the arc welding control method provided in this embodiment, the forward feed and retraction of the welding wire during the arc detection period Ts will disturb the molten pool in the base material. This disturbance will promote the expulsion of air bubbles in the molten pool, thereby improving the weld quality after welding.

[0089] In this embodiment, during the pulse welding period Tp, the welding wire is fed forward at a constant rate. In order to achieve rapid contact between the welding wire and the base material during the arc detection period Ts, it is necessary to set the forward feed rate to the forward feed rate set value Ws1 and maintain it at the beginning of the cooling period Ts1.

[0090] Correspondingly, this embodiment also provides an arc welding control device, such as... Figure 2 As shown, the arc welding control device includes a welding control circuit and a servo motor-controlled wire-drawing welding torch. The welding control circuit provides welding current to the electrodes in each welding cycle. The servo motor-controlled wire-drawing welding torch has a high response speed and precisely controls the wire feed speed and feed direction so that the arc welding control device can perform welding using the arc welding control method provided in this embodiment.

[0091] In this embodiment, the welding control circuit includes a pulse welding current output module and an arc circuit detection current output module. During pulse welding (Tp), the pulse welding current output module outputs a pulsed current to the electrode with pre-set peak current Ipp, base current Ipb, pulse duty cycle, and pulse frequency parameters to achieve droplet-by-drop welding. The arc circuit detection module outputs a droplet separation current Isr to the electrode during arc length detection (Ts). Preferably, the droplet separation current Isr is set to be approximately 50% of the peak current Ipp during pulse welding, around 150 amperes.

[0092] This embodiment does not impose any limitations on the specific structure of the arc circuit detection current output module, which can be a constant current source connected in parallel with the pulse welding current output module. During pulse welding, the electrode is only connected to the pulse welding current output module; while during arc detection, the electrode is only connected to the arc circuit detection current output module. Alternatively, in other embodiments, the arc circuit detection current output module can be integrated with the pulse welding current output module.

[0093] Simultaneously, due to the addition of an arc detection pulse, this pulse possesses the characteristic of low heat input. The energy level is adjusted by utilizing the number of pulses Tp and the ratio of detection pulses within the high-energy cycle, such as... Figure 3 As shown, dual-pulse welding typically uses pulse frequency to control heat input, which often results in a small molten pool during low-energy cycles, causing spatter and blackening. Therefore, this embodiment utilizes the arc detection cycle in the middle proportion of high and low energy cycles to make the 1.6 welding wire more stable during welding, control the welding heat input to improve the clarity of the fish scale pattern, and the arc detection to stir the molten pool helps to expel gas from the molten pool, thereby improving the quality of the weld after welding.

[0094] Therefore, this embodiment utilizes different pulse combinations to achieve the effect of a dual-pulse welding process. The commonly used high-energy cycle ratio of 9:1 is further improved, but should not exceed 25:1. Excessive pulse count increases heat input, and the lengthening of the arc detection cycle reduces its contribution to arc stabilization. In low-energy cycles, multiple arc detection cycles can be combined with pulses, typically in a 4:1 ratio. This ratio can be increased or decreased based on practical heat input requirements. Using only arc detection pulses is not recommended, primarily because this pulse has low heat and high droplet thrust, easily forming finger-like penetration in thick plates, leading to back penetration and an unstable molten pool.

[0095] While the present invention has been disclosed above, its scope of protection is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and all such changes and modifications will fall within the scope of protection of the present invention.

Claims

1. A method for controlling the constant arc length welding of 1.6mm diameter aluminum alloy welding wire, characterized in that, A welding method applied to consumable electrodes includes multiple consecutive welding cycles, each of the welding cycles including a pulse welding period and an arc circuit detection period formed after the pulse welding period; The arc circuit detection period includes: During the forward feeding phase of the welding wire, the welding wire is fed forward at a first constant speed, and the welding wire forms a molten droplet under the welding current, and the molten droplet forms a necking; wherein, the first constant speed is >0; During the first arc detection period, the welding current is reduced to the droplet separation current, and the welding wire is fed forward at a second constant speed to bring the droplet into contact with the molten pool and form a short circuit. At this time, the welding current cannot melt the welding wire, wherein the second constant speed is greater than the first constant speed. During the second arc detection period, the welding wire is fed forward at a third constant speed, and the welding wire and the molten pool are maintained in a short-circuit state, while the short-circuit contact time is set; wherein, 0 ≤ the third constant speed < the first constant speed. During the wire retraction period, the welding wire is retracted at a fourth constant speed to separate the welding wire from the molten pool. At the time of separation, the welding current is set to be maintained at the droplet separation current. The retraction time of the welding wire is set when the welding wire separates from the molten pool, and the welding wire is controlled to maintain a constant pulse arc length. Wherein, the fourth constant speed is less than 0, and the absolute value of the third constant speed is less than the absolute value of the fourth constant speed. The welding method is a dual-pulse welding, and the energy cycle of the dual-pulse welding consists of a high-energy cycle and a low-energy cycle, with the time ratio of the high-energy cycle to the low-energy cycle being 9:1 to 25:

1.

2. The method for controlling the constant arc length welding of 1.6mm diameter aluminum alloy welding wire according to claim 1, characterized in that, The second arc detection period employs constant current control, and the welding current is maintained at the droplet separation current.

3. The method for controlling the constant arc length welding of 1.6mm diameter aluminum alloy welding wire according to claim 1, characterized in that, The pulse welding is achieved by periodically alternating peak current and base current, and the droplet separation current is set to 40% to 60% of the peak current.

4. The method for controlling the constant arc length welding of 1.6mm diameter aluminum alloy welding wire according to claim 1, characterized in that, During the arc circuit detection period, the pulse heat input to the aluminum alloy welding wire base material decreases. By controlling the duration of the arc circuit detection period, the pulse heat is controlled, thereby controlling the formation of molten droplets by the welding wire. The duration of the arc circuit detection period is negatively correlated with the pulse heat.

5. The method for controlling the constant arc length welding of 1.6mm diameter aluminum alloy welding wire according to claim 1, characterized in that, During the wire retraction period, the duration of the wire retraction period is positively correlated with the fourth constant speed.

6. The method for controlling the constant arc length welding of 1.6mm diameter aluminum alloy welding wire according to claim 5, characterized in that, During the wire retraction period, the smaller the fourth constant speed, the shorter the duration of the wire retraction period, resulting in a shorter pulse arc length of the wire.

7. The method for controlling the constant arc length welding of 1.6mm diameter aluminum alloy welding wire according to claim 1, characterized in that, The low-energy cycle uses multiple arc detection cycles and pulse combinations, with the ratio of the number of arc detection cycles and pulse combinations being 3:1 to 5:

1.

8. A control device for constant arc length welding of 1.6mm diameter aluminum alloy welding wire, used to operate and implement the control method for constant arc length welding of 1.6mm diameter aluminum alloy welding wire as described in any one of claims 1-7, characterized in that, The control device includes a welding control circuit connected to the electrode and a servo motor controlling the wire drawing welding gun. The welding control circuit is used to provide welding current to the electrode in each welding cycle; The servo motor controls the wire drawing welding gun to control the feeding speed and feeding direction of the welding wire; The electrode is used to apply current to the welding area through the welding wire.

9. The control device for constant arc length welding of 1.6mm diameter aluminum alloy welding wire according to claim 8, characterized in that, The welding control circuit includes: A pulse welding current output module is used to output a pre-set peak current, base current, pulse duty cycle, and pulse frequency to the electrode during pulse welding to achieve stable, pulse-by-pulse welding; and The arc circuit detection current output module is used to monitor the backflow current of the welding wire pulse arc to ensure welding stability, and to output current to the electrode during arc circuit detection.

Images