Weld bead physics

synergic MIG/MAG · burn-in & dilution · multi-pass V-groove How-to —

Arc & wire

Voltage26.0 V
Wire feed speed8.0 m/min
Wire diameter1.2 mm
Stickout (CTWD)15 mm
Deposition efficiency0.95
Current follows WFS through the wire burn-off law (synergic line): longer stickout = less current at the same WFS. With pulse off, transfer mode is detected from I & V (short-arc / globular / spray, CV machine).

Travel & torch 0 passes

Travel speed60 cm/min
Travel angle (drag + / push −)0°
Torch work angle0°
Torch position 0.0 mm
Every deposit snapshots the full arc + torch state — change settings between passes to model root / fill / cap procedures. Drag deepens penetration, push flattens and widens.

Thermal state interpass

Interpass temperature20 °C
Heat accumulation between passes0.75
substrate temp @ torch—
After Manokruang 2022 (CMT WAAM thesis, in reference/): wetting angle falls near-linearly with substrate temperature while deposited area stays constant — hot passes spread flat and wide, cold ones sit ropy. Heat builds up pass over pass (0 = each pass starts at interpass temp, 1 = nothing cools). Too hot → slump flag.

Next bead physics live preview

penetration (max)—
95 % process-noise band—
KTH fillet model (2019)—
bead face angle θ—
est. dilution—
Target penetration3.0 mm
P[ pen ≥ target ]—
Process noise per Mansour et al. 2019 (KTH): ±10 % on V and I (correlated through the power-source slope), ±5 % travel speed, ±3° angle. A set-up that hits the target on average only makes it ~50 % of the time — aim for ≥ 90 %. The KTH number is their 81-weld fillet fit, shown as a reference; outside V 28–40 / I 200–420 / TS 30–60 / angle 20–30° it extrapolates.
passes placed0
courses0
groove fill0 %
last bead h × w—
last bead burn-in / dilution—

Job export schedule.json

Course grouping 0.50
Cap courses2
Same contract as the v6 packer (jbi_gen.py reads layer/xc/cy/lean) plus per-bead physics: current, heat input, penetration, dilution, mode.
Groove geometry
Depth14.0 mm
Wall angle (from vertical)20°
Root gap4.0 mm
Changing the groove clears all passes.
Physics tuning
Arc efficiency η0.80
Penetration gain1.00
Wetting gain1.00
HAZ scale1.00
Thermal wetting (°θ / 100 °C)8
Calibration knobs against macro sections. They affect the preview and future deposits — committed beads keep the physics they were welded with.
Generated Yaskawa .jbi jobs