Suban Part B1 ChaosWeld

European Research Council

ERC Starting Grant

Research proposal (Part B1)

New approach to welding control using chaos theory

ChaosWeld
FOR MORE INFORMATIONS VISIT http://sites.google.com/site/chaosweld/

- Name of the Principal Investigator (PI)

Marjan Suban
- Name of the PI's host institution for the project
Institut za metalne konstrukcije
- Proposal full title
New approach to welding control using chaos theory
- Proposal short name
ChaosWeld
- Proposal duration in months
60 months

In arc welding processes, the knowledge of material transfer (electrode melting, droplet formation
and transfer to the weld pool) is essential to analysis and control of welding process. This is
especially important in welding processes, which are used in automation or robotisation, where
more stable welding process is required (e.g. MIG/MAG). Material transfer mode affects stability of
the welding process, which finally affects the quality of welded joints.
For many years, the welding community has assumed that the material transfer is stohastic process.
In early studies in 1999 and 2000, we have already indicated that it is possible to detected signs of
chaotic behavior in the short circuiting transfer. In later studies it was found that the chaotic
behavior also appearing in globular transfer of material.
The current state of welding technology enables stable transfer of material using pulse mode
welding. The material transfer from the electrode to the weld is subject to high energy puls forming
drop and forces it to move into weld pool during one pulse. Disadvantages of this welding mode are
many, such as high energy consumption, high energy input in the weld, a strong UV radiation in the
surrounding area, the inadequacy for root welding etc.
Given the above, one can conclude the following. If the process of material transfer from electrode
to the weld pool is chaotic and not stohastic, then it’s possible to achieve stable transfer and thereby
stable welding process using the theory of chaos control. One of the characteristics of the chaotic
process is sensitivity to initial conditions. If we apply an approach that is used in heart pacemakers,
then the process of material transfer and thereby the welding process can be controlled by very
small system perturbations, which can lead to stable and predictable process. This method of control
the welding process could have revolutionary impact on the design of welding equipment and
related control systems.

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Section 1: The Principal Investigator

1(a) Scientific Leadership Potential

My interest for the welding domain already originate from my home
environment. On this basis, I have built my way of education. After
completing undergraduate studies where I was in last year decided for a
module "welding and cutting", I have on the basis of good grades obtaining a
fellowship in the program "Young researchers" by the Ministry of Science
and Technology (now Ministry of Higher Education, Science and
Technology ). Based on the obtained grant I got a job at the Institute of welding in Ljubljana as a
researcher and began post-graduate study. During this time I also completed post-graduate
specialization for European Welding Engineer EWE, which has brought me additional practical
knowledge of welding and cutting.

As young researcher I successfully completed the postgraduate studies in the field of High-
production fusion arc welding in various shielding media. In the Master’s thesis, investigation was
made including research on welding productivity and latest variations of MIG/MAG welding
processes. MIG/MAG welding processes was my main research object with different types of wire
and also various shielding gases. During the study of the subject »Synergetics«, I came familiar
with the theory of chaos, which until then I did not sufficiently known. On the basis of knowledge
in the study of this subject and knowledge which I already have in the field of MIG/MAG welding
process in 1999 I came to the idea that it would be possible to combine these two disciplines
together.

Thus began my research in the field of chaos theory in welding and in year 2000 I presented my
work on 53rd IIW Annual Assembly in Florence, Study group 212 (Physics of welding) in a form
of lecture and document No. 212-985-00 with title »The chaotic behaviour of the material transfer
in GMAW: preliminary report«. Presented paper treated some thoughts on the analysis of the
material transfer during gas-shielded metal-arc welding based on nonlinear dynamics. Based on
chaos theory and research work on dripping faucet by other researchers, some similarities can be
found between the material transfer in GMAW and the water drops falling from a dripping faucet,
which is one of the basic models of chaotic system. In this preliminary study I have also pointed out
the direction on further research work in area of arc control.This can lead to improved arc stability,
which is important for determination of weld quality.

During this period, beside mentioned areas, I also participated in many research areas or projects,
such as the before mentioned research of productivity of welding, welding process stability, quality
of welded joints and environmental problems of welding and soldering. My first large scale project
that I conducted under the supervision of project leader dr. Janez Tušek was entitled »High-
productivity arc welding«. Project results were also applicable from the industry point of view. The
common subject of all the projects in which I participated was welding and allied processes. In
implementing the projects I have successfully worked with various leaders. This period was very
fruitful in a research sense, since in this period also derive most of my publications in scientific
literature. Published contributions were of interest to other researchers, since I have gained some
citations.

In this period, I was promoted as Head of Training Center at the Institute of welding. I was mainly
involved in the implementation of European and internationally recognized post-graduate
specialization for welding technologists EWT, engineers EWE and inspectors EWI in Slovenia as
well as in Serbia. In this field, I worked tightly with European Federation for Welding, Joining and
Cutting EWF and International Institute of Welding IIW/IIS, commission C-XIV Education and

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training. At that time, the opportunity was offered to me to begin post-graduate study at the Faculty
of Economics in Ljubljana. I started study entrepreneurship in year 2007, which I still attended. I
have plan to finish study in year 2010.

I continue to Ph.D. study, where I also was co-financed by the Ministry of Science and Technology.
While studying I had to change jobs, so I went to the company Goodyear EPE, where I also got a
job in R&D departament. This area was new for me, because I had to get to know the rubber
products and their characteristics. In this company I completed my Doctoral study, by the fact that I
had allowed partial access to research equipment that I had at the Institute of welding. The thesis I
have also discussed productivity in MIG/MAG welding, but mentor dr. Janez Tušek and I set the
task in a different way. Goal of the thesis was design and development of welding equipment and
research of gas shielded pulsed welding technology using three wires. New and in some way
innovative welding machine was built. Unlike existing welding machines, the essence of our
machine was in a single welding power source with a newly developed control electronics. The
welding equipment developed satisfied all the demands for stable pulsed welding using multiple-
wire and it results in an increase of productivity. Developed welding equipment remained the
property of the Institute of welding, but further development as well as potential marketing never
occur.

Working in the company Goodyear EPE was extremely project oriented with a lot off team work.
For the various producers (Scania, Volvo, Renault) I participated in development projects for trucks
and buses suspension. There was a lot of research work within the Goodyear company itself, but
this was mainly focussed on the development of rubber products and their testing. Together with the
head of development for Europe we founded a research group in the company that also participated
in three national projects and one international research project. Publication of articles from this
period are rare, since the results of research group were often treated as business secrets.

With global sale of division, development in the company Goodyear EPE was reduced, so I was
forced to change job and I went to the Ministry of Higher Education, Science and Technology. With
this, I break the job in research field. At the time of service at Ministry I was involved in the
creation of science policy in particular in the transfer of knowledge from the academic sphere in the
industry. Based on the successful work, national achievements in the transfer of knowledge was
internationally presented as one of the five examples of good practice in Europe.

Following the work in the company Litostroj Steel, where I worked on the project of purchase and
start-up foundry in Serbia, I came to the Institute for metal constructions as Head of R&D. With this
I again returned to the research field. Institute in the past was very strong national institute in the
development of steel welded structures. In recent years the development of the Institute has
declined and that it should be reinvigorated. This offered me the opportunity to re-engage in
research work in the field of welding. Reestablishment research group at the Institute is for me
challenge which I’am currently facing. This grant application is an element of this mission, to build
a excellent research team, which in the future will produce great results.

Self Evaluation
I have a twelve years long experience as a researcher, where nine years are in a field of welding and
allied processes. I think I have strong background in formal and additional education. My work in
many different projects was respected. I worked in project teams with different project leadears
mainly as a researcher. I just started to apply for a funding as a project leader. I have also a
education and experiences in the field of finances and a science policy (beside illness this time also
represent my research career break). Thus I think that all these skills demonstrate my potential to
become a good independent research leader.

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1(b) Curriculum Vitae

Education
2007 - M. Sc. study Entrepreneurship
University of Ljubljana, Faculty of economics
2000 - 2004 Ph. D., 14 Dec. 2004
University of Ljubljana, Faculty of Mechanical Engineering
1995 - 1998 M. Sc.
University of Ljubljana, Faculty of Mechanical Engineering
1989 - 1994 B. Sc.
University of Ljubljana, Faculty of Mechanical Engineering
1984 - 1988 Technician
Secondary school of Mechanical Engineering, Ljubljana

Additional Education:
2007 Project and Programme Manager
Europe Training Center Paris
1994 European Welding Engineer (postgraduate specialization)
Institute of welding, Ljubljana

Professional Experience
2009- Head of R&D
Institut za metalne konstrukcije, Ljubljana (Institute of metal constructions)
2008 - 2008 Project leader
Litostroj Jeklo, Ljubljana (Litostroj Steel)
2006 - 2008 Undersecretary
Ministrstvo za visoko šolstvo,znanost in tehnologijo (Ministry of higher education,
science and technology)
2002 - 2006 R&D engineer
Goodyear EPE, Kranj
1997 - 2002 Head of Training Center
Institut za varilstvo, Ljubljana (Institute of welding)
1994 - 1997 Researcher
Institut za varilstvo, Ljubljana (Institute of welding)
Teaching Experience
1996 - 2002 Lecturer (welding processes, metal constructions), postgraduate specialization for
European Welding Personal, Institut za varilstvo, Ljubljana (Institute of welding)
1998 - 2000 Assistent, University of Ljubljana, Faculty of Mechanical Engineering

Professional Membership
1994 - Zveza drustev za varilno tehniko Slovenije (Slovenian Welding Society)
1996 - 2002 International Institute of Welding IIW/IIS, national delegate in study group SG-212
The physics of welding, commission C-XII Arc welding processes and production
systems and commission C-XIV Education and training

Fellowship
1999 - 2001 Young researcher (Ph. D. study), Ministry of Science and Technology
1995 - 1997 Young researcher (M. Sc. study), Ministry of Science and Technology

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Collaboration in National research groups (Slovenian Research Agency)

2009 - 0218-001: Institut za metalne konstrukcije (Institute for metal constructions), Head
of research group
2002 - 2006 Goodyear EPE, Researcher
1994 - 2002 0209-001: Institut za varilstvo (Institute of welding), Researcher

Research Projects
2005 - 2008 »Development of forecast tools for drive belts endurance«, L2-7288 Slovenian
Research Agency, Faculty of Mechanical Engineering in collaboration with
Goodyear EPE (with dr. Marko Nagode as Project Leader), 165.200
2005 - 2006 »Characterization of the failure mechanisms of elastomer composites under cyclic
loads«, Institute of Materials Science and Testing of Plastics, University of Leoben,
Leoben, Austria, Polymer Competence Center Leoben GmbH, Leoben, Austria co-
operation contract with Goodyear EPE (with dr. Zoltan Major as Project Leader),
153.000
2004 - 2005 »Laser triangulation method in shape measurement of rubber products«, Faculty of
Mechanical Engineering co-operation contract with Goodyear EPE (with dr. Janez
Mozina as Project Leader), 88.000
2002 - 2004 »Lack of fusion in MAG welding of high-strenght steels«, L2-4409 Ministry of
Education, Science and Sport, Researcher (with dr. Gabriel Rihar as Project Leader),
52.200
2001 - 2004 »TIG welding of austenitic stainless steels in a protective atmosphere of nitrogen«,
L2-3252 Ministry for Education, Science and Sport, Researcher (with dr. Borut Zorc
as Project Leader), 280.900
2000 - 2002 »Replacement of materials and technology of soldering for melting elements
application«, L2-2241 Ministry of Science and Technology, Researcher (with dr.
Janez Tusek as Project Leader), 87.400
2000 - 2002 »Effect of welding procedures and parameters on the mechanical properties of welds
of different aluminum alloys«, L2-2167 Ministry of Science and Technology,
Researcher (with dr. Gabriel Rihar as Project Leader), 112.500
1999 - 2003 »Transfer of welding multimedia software – WELDICTION«, Leonardo da Vinci
project Nr. EUR/99/2/07364/PI/II.1.1B/FPC, Researcher
1999 - 2001 »Manufacturing and processing of working surfaces of tools by welding«, L2-1649
Ministry of Science and Technology, Researcher (with dr. Janez Tusek as Project
Leader), 115.300
1997 - 1998 »Welding of high pressure gas pipelines in service«, L2-9067 Ministry of Science
and Technology, Researcher (with dr. Gabriel Rihar as Project Leader), 74.100
1996 - 1998 »High-productivity arc welding«, L2-7642 Ministry of Science and Technology,
Researcher (with dr. Janez Tusek as Project Leader), 231.800

Funding ID
I’am employed for a specified period till 31.5.2009 with possibility of employment for an indefinite
period at the Institut za metalne konstrukcije as Head of R&D. At a moment I’am not receiving any
research grant or fellowship. There is one ongoing application, where results will be known on
9.4.2010, with following details:
2010 - 2012 »Study of effects on the initiation and development of microbial influenced
corrosion«, Slovenian Research Agency, Project Leader Marjan Suban, 110.000

Significant Career Break

nov. 2008 - maj 2009 Long-term illness
maj 2006 - apr. 2008 Employment in Non-Research Institution
nov. 2005 - apr. 2006 Long-term illness

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1(c) Early Achievement-Track-Record

Citation report for Marjan Suban (source WoS):

Results found:8
Sum of Times Cited: 59
Average Citations
per Item: 7,38

Publications without the PhD Supervisor (dr. Janez Tusek)

SUBAN, Marjan. Determination of stability of MIG/MAG welding process. Qual. reliab. eng. int.,
2001, Vol. 17, No. 5, pp. 345-353. [COBISS.SI-ID 861633], Times cited: 2
Description: The paper treats several methods of evaluating the stability of MIG/MAG welding
processes, which are based on measurement of time-varying welding-current intensity and welding
voltage.

Publications with the PhD Supervisor (dr. Janez Tusek)

SUBAN, Marjan, TUSEK, Janez. Methods for the determination of arc stability. J. mater. process.
technol.. [Print ed.], 2003, Vol. 143, Special Issue., pp. 430-437, Times cited: 2
Description: The methods described in the paper are based on measurement of time-varying
welding current and welding voltage. Stability analysis was carried out with different gas-shielding
atmospheres.

TUŠEK, Janez, SUBAN, Marjan. High-productivity multiple-wire submerged-arc welding and

cladding with metal-powder addition. J. mater. process. technol.. [Print ed.], 2003, Vol. 133, No.
1/2, pp. 207-213. [COBISS.SI-ID 5627163], Times cited: 6
Description: It was found that the multiple-wire submerged-arc welding and cladding with metal-
powder addition will increase the deposition rate, and the welding-arc efficiency and reduce the
shielding-flux consumption.

SUBAN, Marjan, TUŠEK, Janez. Dependence of melting rate in MIG/MAG welding on the type of
shielding gas used. J. mater. process. technol.. [Print ed.], 2001, Vol. 119, No. 1/3, special issue
"AMPT'99", part 2, pp. 185-192. [COBISS.SI-ID 4892443], Times cited: 12
Description: The paper describes a study on welding productivity, i.e. melting efficiency of the filler
material (solid and cored wires) in various shielding media. A mathematical model for prediction of
a melting rate is presented too.

SUBAN, Marjan, TUŠEK, Janez, URAN, Miro. Use of hydrogen in welding engineering in former
times and today. J. mater. process. technol.. [Print ed.], 2001, Vol. 119, No. 1/3, special issue
"AMPT'99", part 2, pp. 193-198. [COBISS.SI-ID 4892699], Times cited: 2
Description: This paper deals with the history of the use of hydrogen as a combustible or shielding
gas in welding and with a study on the use of an argon mixture containing a larger portion of
hydrogen in TIG and MIG welding processes.

TUŠEK, Janez, KAMPUŠ, Zlatko, SUBAN, Marjan. Welding of tailored blanks of different
materials. J. mater. process. technol.. [Print ed.], 2001, Vol. 119, No. 1/3, special issue "AMPT'99",
part 2, pp. 180-184. [COBISS.SI-ID 4892187], Times cited: 5

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Description: Article treats selection of appropriate welding procedure of tailored blanks made of
high-alloy stainless and low-alloyed ferrite steel.

TUŠEK, Janez, SUBAN, Marjan. Experimental research of the effect of hydrogen in argon as a
shielding gas in arc welding of high alloy stainless steel. Int. j. hydrogen energy. [Print ed.], 2000,
Vol. 25, pp. 369-376. [COBISS.SI-ID 473537], Times cited: 13
Description: Effect of hydrogen in argon as a shielding gas in TIG and MIG welding of austenitic
stainless steel on arc stability and melting efficiency is studied.

TUŠEK, Janez, SUBAN, Marjan. Hybrid welding with arc and laser beam. Sci. technol. weld. join.,
1999, Vol. 4, No. 5, pp. 308-311, [COBISS.SI-ID 424129], Times cited: 15
Description: The major part of the paper is focused on the combined action of a welding arc and a
laser beam (synergic action of two different heat sources for fusion welding). The main advantage
of the use of both heat sources is more efficient use of the energy supplied.

Publications in peer-reviewed conferences proceedings

SUBAN, Marjan, TUŠEK, Janez. The effect of the shape of welding wire tip on arc ignition in
MIG/MAG welding. V: TORRALBA, José M. (editor). Proccedings of the International
Conference on Advanced Materials Processing Technologies (AMPT'01), 18-21 September,
Universidad Carlos III de Madrid, Leganés, [Madrid], Spain. Vol. 1, New developments on metals.
[Madrid]: Universidad Carlos III de Madrid, 2001, Vol. 1, pp. 447-453. [COBISS.SI-ID 832193]
Description:

Invited Presentation
PICIGA, Darja, SUBAN, Marjan. Technology transfer area: Presentation of "A Center of
excellence" (Slovenia) : [invited lecture on Fostering regional innovation in Europe: Novaregio
Best Practices Showcase, Santa Cruz de Tenerife, Instituto Technologico de Canaries S.A., 4th
October 2007}. Santa Cruz de Tenerife, 2007. [COBISS.SI-ID 1030337]
Description: The concept of Centres of excellence (Ministry of Higher Education, Science and
Technology) was presented as one of the five best practice of knowledge transfer from the academic
sphere in the industry in Europe.

Peer-reviewer for International Journals

Journal of Materials Processing Technology, Impact Factor: 1.143
Optics and Lasers in Engineering, Impact Factor: 1.103

Organisation of International Conferences

54th Annual Assembly of the International Institute of Welding IIW/IIS in Ljubljana, July 2001
(organizing committe member)

Organisation of National Conferences with International Participants

Dan varilne tehnike (Day of welding) 2000 in Ljubljana, 2001 in Krsko and 2002 in Portoroz
(organizing committe member)

Membership in Editorial Boards

2nd Dan varilne tehnike, Ljubljana, 13. april 2000, POLAJNAR, Ivan (editor), SUBAN, Marjan
(editor). Proceedings. Ljubljana: Društvo za varilno tehniko, 2000. 181 pages, ilustrations
[COBISS.SI-ID 106907904]
4th Dan varilne tehnike, Portorož, Koper, 23. May 2002, POLAJNAR, Ivan (editor), SUBAN,
Marjan (editor). Proceedings. Portorož: The Faculty of Maritime Studies and Transport, 2002. 203
pages., ilustrations. ISBN 961-6044-50-8. [COBISS.SI-ID 118397440]

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Section 1d: Extended Synopsis of the project proposal

The gas shielded metal arc welding (MIG or GMAW) process was successfully developed in 1948
in USA. One of the basic changes that made the process more usable was the small-diameter
electrode wires and the constant-voltage power source. The initial introduction of GMAW was for
welding nonferrous metals. The high deposition rate led users to try the process on steel. The cost of
inert gas was relatively high and the cost savings were not immediately available. In 1953, Russian
researcher announced the use of welding with consumable electrodes in an atmosphere of CO2 gas.
The MAG welding process immediately gained favor since it utilized equipment developed for inert
gas metal arc welding, but could now be used for economically welding steels. The process became
widely used with the introduction of smaller-diameter electrode wires and refined power supplies.
Another variation was the use of inert gas with small amounts of oxygen that provided the spray-
type arc transfer. It became popular in the early 1960s. A recent variation is the use of pulsed
current. The current is switched from a high to a low value at a rate of once or twice the line
frequency. With pulsed current material transfer can be controlled, but pulsed current have also
some others limitations (not suitable for root welds, high UV radiation, etc.). In 1990 with inverter-
based power sources many others welding process control was developed in order to control
material transfer from wire to the weld pool. As example, one of this was Surface Tension Transfer
™ in late 1993.

As shown in this history review a lot of research work was put in the development of stable material
transfer where we can achieve high productivity of welding with low energy consumption. This is
especially important with the introduction of automation and robotisation in industry where it also
requires real-time monitoring and control of welding processes.

Further development in this area is obvious. Material transfer most be fully controllable in any
mode of welding, from low to high welding current, for thin or thick sheets of metal. Is material
transfer in welding stochastic or deterministic process? We know that it is not deterministic. So, it
must be stochastic. But what if it is non of this. What if it is Chaotic?

Dynamical systems are »deterministic« if there is a unique consequent to every state, and
»stochastic« or »random« if there is more than one consequent chosen from some probability
distribution (the »perfect« coin toss has two consequents with equal probability for each initial
state). But there also exists a system, which contains »deterministic« and »stohastic« properties and
is called »chaotic system«. It has been said that »Chaos is a name for any order that produces
confusion in our minds«. However, the mathematical definition is, roughly speaking: chaos;
effectively unpredictable long time behavior arising in a deterministic dynamical system because of
sensitivity to initial conditions.

Some nonlinear systems which display deterministic chaos are: forced pendulum, lasers, nonlinear
optics devices, chemical reactions, plasmas with interacting nonlinear waves, stimulated heart cells,
etc. In 1977 Rössler suggested that the drops falling from the leaky faucet might provide a familiar
example of a dynamical system capable of exhibiting chaotic behavior. The dripping faucet is since
then well known model system, used for illustrating the appearance of chaotic behavior in nonlinear
systems. The experiment (see Fig. 1) studies the statistic of liquid drops dripping from a leaky tap
when the mean dripping rate (control parameter of system) is increased.

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Figure 1: Schematic setup of the apparatus of dripping faucet

As I was looking at drops falling from a dripping faucet, I saw in my mind similarity between this
process and material transfer in gas-shielded metal arc welding or MIG/MAG for short, where a
material separates from the molten wire as a droplet and "falls" to the plate.

The physics of the droplet transfer process is more complicated than that of the dripping faucet. In
addition to surface tension and gravity, and the interaction with the power supply dynamical
response, the conducting droplets are subjected to complicated electromagnetic forces, along with
arc plasma forces. Nonetheless, generic properties of the droplet release dynamics could just as well
give rise to low dimensional dynamics as they can in the conceptually simpler, dripping faucet case.
Indeed, in the globular mode, where the droplets are more massive, gravity and surface tension tend
to dominate as they also do in the dripping faucet case.

MIG/MAG welding process exhibits many different mode of material transfer. Principle transfer
modes in MIG/MAG welding are:
• short-circuit,
• globular,
• spray.
The droplet events can be identified from visual observation of droplet processes (as in a case of
dripping faucet – Fig. 1), or from air or plate-borne acoustic emission or from signature effects in
weld voltage and current (Fig. 2). Perhaps, the most problematic will be observation of droplet
separation in the spray mode because of the weakness of the event signatures. Construction of map
time series with some missing points or extra points is not very competent. Based on measured time
intervals we can diagnosticate them, with the emphasize on chaotic behavior.
Some basic research was done in 1999 in 2000 when I have started to work in this research topic.
Since then I have found only a few articles published on this matter. They were mainly dealing with
search for chaotic behaviour in short-circuit or globular material transfer mode.

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Figure 2: Material transfer in MIG/MAG welding (globular mode)

The question is why we are trying to find chaotic behavior in material transfer? The answer is:
controlling chaos.

One of the basic properties which deterministic chaos manifests is »a sensitive dependence on
initial conditions« (the butterfly effect). It becomes therefore practically impossible to predict the
long-time behavior of these systems. It must be emphasized that a deterministic dynamical system
is perfectly predictable given perfect knowledge of the initial condition, and is in practice always
predictable in the short term. The key to long-term unpredictability is a property known as
sensitivity to (or sensitive dependence on) initial conditions.

Even if the behavior is chaotic, it can be controlled once the rules are known. Within the chaos exist
unstable periodic orbits: state values that, if they were supplied and iterated with infinite precision,
would repeat over and over. Of course, any slight imprecision in this state causes successive iterates
to wander away from the cyclic order and take on the complexity of the chaotic attractor.
Nonetheless, in some simple situations the chaotic dynamics can be forced to track arbitrarily close
to a specified unstable orbit by aplying small, well-timed perturbations. The control of chaos by
unstable periodic orbits embedded in a chaotic attractor was first originated in the work of others
scientists. Furthermore, it is possible to switch efficently from one unstable periodic orbit to
another.

As mentioned befor we can use pulsed current so that material transfer can be controlled (see Figure
3). But this arise new problems. Puls of welding current forced melted droplet to transfer in exact
time from welding wire to weld pool. Energy consumption is in this case large. Also high UV
radiation of welding arc is one of the effects that welders don't like. In the case of chaotic behaviour
of material transfer it can be controlled by vary small perturbations or pulses (see Figure 4-left)
which can lead in a stable controlled droplet transfer.

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Figure 3: Material transfer in pulsed arc welding (one drop per puls)

Figure 4: Typical form of pulsed welding current (left) and anticipated form of welding current
based on theory of chaos control (right)

In short we can put research work in this project in following working packages. First working
package will be identifying chaotic behaviour in material transfer in MIG/MAG welding. One of
the steps in our research could also be searching for chaotic behavior in known mathematical
models of MIG/MAG processes, such as different n-order nonlinear differential equations
developed by others researchers or my research team.The next working package in our research
work will be construction of an model for material transfer in different modes based on a model for
the dripping faucet. Identification of chaotic behavior in the material transfer could permit the
development of improved control of welding through well-known methods of control of chaos.
Improved control can lead to improved arc stability, which is important for determination of weld
quality. As final, prototype of welding control unit will be made. Findings in the field of MIG/MAG
could then be transfered also to the other welding processes such as submergeed arc welding SAW
or manual metal arc welding MMA.

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Short economic background

Results of this project will be usefull for a producers of welding equipment for semi or fully
automated. In this field producers in Europe (the bigest are Germany, Austria, Finland, Sweden and
France) represent 67% of world export or in total 1.173. mio USD. World exporters of welding
machines with values (HS Code 851531 Elec mach&app for arc inc plasma arc weldg of met
fully/partly auto) are also presented in Figure 5. Main importers of this products are Russian
Federation, China and USA with total value of 496 mio USD.

Figure 5: Map of exporters for welding machines in 2008 (source COMTRADE)

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