Review of Wire Melting Control using High Energy Density Heat Source

As the industrial demand for welding with wire continues to rise, significant researches are directed toward monitoring and controlling wire transfer to ensure consistent welding quality. In this review paper, we introduce wire welding techniques using high-density energy sources such as laser and electron beams. Welding with wire, capable of covering various shapes and gaps, requires appropriate control of the melted wire transfer process. Wire transfer in melting processes can be classified into drop and bridge transfer. Studies indicate that bridge transfer produces a uniform bead, whereas drop transfer results in variable volumes depending on the transfer cycle, often leading to the formation of humping beads and spatter. By integrating these suggestions, we suggest a way to realize high-quality welding with wire to be used in industrial applications.