Information from the abstract
Abstract The automotive industry is transiting toward carbon neutrality. Optimizing energy intensive manufacturing processes like Gas Metal Arc Welding (GMAW) has become an important aspect. This research provides a multi-dimensional comparative analysis of standard current and pulsed current waveforms for welding SPCC cold-rolled steel (1.2 mm and 2.8 mm thickness), specifically evaluating their contribution to energy consumption, productivity, and Scope 2 carbon emissions. All tested configurations were validated for structural integrity conforming to AWS D1.3 standards. There were 7 types of welding in this study, but only 5 types could be passed conforming to AWS D1.3 requirements. The time study was implemented to determine Standard Time which considered rating factors and industrial allowances. Power measurement was performed for both input and output sides of welding machine. Results for 1.2 mm thin-gauge specimen showed that pulsed current welding reduced unit energy consumption and carbon emissions by 14.26% compared to Standard current welding. For 2.8 mm specimen, a "Productivity Paradox" was identified: while the pulsed current welding required higher peak power, its character to achieve complete joint penetration in a single-pass with square butt configuration that eliminated the requirement for the V-groove preparation and double-sided welding required by the standard current welding. This led to a 59.89% reduction in Standard Time and a 58.87% decrease in total operational costs. By estimating annual impact for producing 100,000 units, switching to Pulsed GMAW with 180,000 THB investment would pay back within 5.793 months through energy and labor-saving providing a compelling economic benefit for manufacturers to invest in and implementing pulsed current welding machines on the production floor. The findings confirm that pulsed current welding could provide pathways for compliance with reduction of carbon emissions with low capital expense strategy for achieving "Green Industry" objectives in high-volume automotive production.
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This record has an Impact Signal of 85/100 based on recency, source, collaboration, and bibliographic signals. It prioritizes monitoring and is not a judgment of research quality.
Related topics: Welding Techniques and Residual Stresses · Energy Efficiency and Management · Advancements in Materials Engineering
Thai researcher and institutional participation
Isaratat Phung-on · Napongphan Traiyapanich · Kritsada Naksawat · TK Thammarak Sodarak · Somporn Peansukmanee · King Mongkut's University of Technology Thonburi
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