In non-pulsed gas metal arc welding (GMAW), spatter can be reduced by lowering the short-circuit current to a low level just before the re-arcing. The reduction of spatter requires an improvement in the accuracy of predicting the re-arcing by stabilizing the metal transfer and improving the robustness of the accuracy against disturbances. The controlled bridge transfer (CBT) process optimizes the accuracy of predicting the re-arcing in real time in response to the metal transfer, realizes spatter reduction and stable arc in non-pulsed GMAW. Traditionally, GMAW is carried out using electrode positive polarity. However, this polarity is not sufficient for welding extra-thin steel sheets, specifically those thinner than 1.0 mm. With electrode negative (EN) CBT process, although slight arc voltage fluctuation occurs caused by behavior of cathode spots on the tip of the wire during EN polarity GMAW, instantaneous voltage is used command computation to improve the transient response against the disturbance. Consequently, a stable arc can be obtained without increasing the number of short circuits in a unit time to obtain spatter-free welds.
