Abstract: A novel and high effective double-electrode gas metal arc welding(DE-GMAW) method has been introduced. Due to the instability and poor formation of DE-GMAW, a new decoupling control plan is put forward. This implementation decoupling control plan controlled the bypass arc by adjusting the bypass feed speed, and controlled the base metal current by adjusting the bypass current. The simulations about this plan are carried out and analyzed. Then, by using rapid prototyping, the welding experiment of decoupling control plan is carried out. The results show that, the decoupling control can steady the welding process and motherboard current; and a better stability, faster response and higher accuracy of the bypass arc control can be gotten. A good weld appearance is also obtained.

Key words: Control, Gas metal arc welding, Simulation, Welding arc, Contact pattern, Edge tooth contact analysis, instantaneous conjugate contact curve, Transmission errors, Tooth contact analysis