A review of double-electrode GMAW: Approaches, developments and variants

Abstract

Double-electrode gas metal arc welding (DE-GMAW) is an advanced welding technology that uses a bypass torch to regulate the current through the base metal, effectively reducing the heat input to the base metal and increasing the deposition rate of the filling wire. Through precise control of the welding process, the stability of the welding arc and the welding quality are significantly improved. First, this paper provides a systematic review of the characteristics and applications of consumable and non-consumable DE-GMAW. The non-consumable DE-GMAW includes single-bypass GMAW (SB-GMAW), double-bypass GMAW (DB-GMAW), and pulsed bypass GMAW (PB-GMAW). Then, we compare the current state of various DE-GMAW technologies, highlighting differences in welding productivity, stability control, and energy efficiency. The goal is to offer practical guidance for researchers in practical applications. Furthermore, this paper explores the innovative applications of DE-GMAW technology in other welding methods, such as submerged arc welding (SAW), twin-wire indirect arc welding (TWIAW), and double-side arc welding (DSAW), and analyzes the advantages of these hybrid processes in enhancing welding performance. Finally, this paper points out that the future development of DE-GMAW technology requires further theoretical research, exploration of new material welding processes, and the application of automation systems and robotics technology to further improve the welding efficiency, accuracy, and repeatability in the application process.