Abstract No.:	4641
Scheduled at:	Wednesday, May 11, 2016, Room 3H + 3I + 3J 4:20 PM Arc Spraying & Laser Spraying
Title:	Cause study to the occurrence of unmelted wire pieces during wire arc spraying
Authors:	Werner Mayr* / University of applied sciences Munich Department of Electrical Engineering and Information Technology, Germany Erwin Steiner / University of applied sciences Munich Department of Electrical Engineering and Information Technology, Germany Stefan Heilmeier/ University of applied sciences Munich Department of Electrical Engineering and Information Technology, Germany Alexander Atzberger/ Universitaet der Bundeswehr Muenchen, Germany Stefan Kirner/ Universitaet der Bundeswehr Muenchen, Germany Karsten Hartz-Behrend/ Universitaet der Bundeswehr Muenchen, Germany Stephan Zimmermann/ Universitaet der Bundeswehr Muenchen, Germany Jochen Schein/ Universitaet der Bundeswehr Muenchen, Germany Michal Szulc/ Zierhut Messtechnik GmbH, Germany
Abstract:	To investigate the occurrence of unmelted wire pieces during wire arc spraying, a mobile measuring setup has been developed to synchronously record the following quantities: - Fluctuations of arc voltage and arc current with a sampling rate of 1MS/s - The wire feed velocity, acquired in consecutive millisecond intervals at different locations of the feed unit - Camera images to record the visual behavior of the arc and the wire ends The system is provided with pre trigger capabilities to capture even rarely occurring cold shuts (unmelted wire pieces). Additional new configurations of shadow- and high-speed-recordings are tested for the determination of unmelted wire pieces. Here the main research focus was to enhance the image processing algorithm. Furthermore the test and use of individual band-pass- and grey filter for the optimal illumination and elimination of the plasma noise were also part of this research work. The measuring equipment is applied to different wire arc spraying facilities and operating conditions. The latter are ignition, and activated cold shuts as well as instable, new and standard spraying parameters. The results will be discussed and guidelines are developed to avoid cold shuts.

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