Comprehensive review on comparative performance of advanced welding techniques for different materials using rotating arc metal inert gas welding and cold metal transfer welding

Rotating Arc Metal Inert Gas Welding (RAMIGW) has become increasingly popular due to its practical applications. Rotation-based arc MIG welding achieves higher deposition rates with low heat input and enhanced weld quality through electrode motion, resulting in uniform material distribution and improved penetration with minimal spatter. It also offers greater flexibility compared to traditional MIG welding. It finds extensive application in constructing large metal structures, where its speed and flexibility are in high demand. The CMT process represents a significant advancement over conventional MIG welding. It features a low-heat-input source, ensuring smoother, cleaner surfaces with minimal spatter, ideal for precision welding. Rotation Arc welding is generally used for welding thick materials, whereas CMT has minimal distortion and is used for welding thin materials. Comparing these two advanced welding processes provides a deeper understanding of how controlled arc dynamics impact the microstructure, mechanical properties, quality, and joint strength, ultimately leading to the optimal technique for achieving high-quality performance in industrial applications. This article delves into the principles of RAMIGW and CMT, exploring their mechanisms while highlighting their impact on the mechanical properties and microstructures of processed metals and alloys. Notably, alloys of titanium, nickel, steel, and aluminum fabricated using RAMIGW demonstrate mechanical properties comparable to or surpassing those of cast and wrought materials, making them suitable for demanding industrial applications. However, challenges such as high residual stresses, porosity, delamination, Lack of Fusion, undercutting, Spatter, Distortion Inclusions, Cracking, Burn-Through, Overlapping, Cold Lap, Excessive Penetration, Heat-Affected Zone Softening and fractures often arise during the process, necessitating effective defect-reduction strategies such as Advanced Process Control, Enhanced Wire Feeding Systems, Optimized Shielding Gases, Improved Filler Materials, Automated and Robotic Welding, Enhanced Cooling Techniques, and Data-Driven Quality Assurance to enhance weld quality. By addressing these issues and presenting advancements in RAMIGW technology, this study underscores its potential as a reliable solution for achieving high-quality production, positioning it as a promising alternative for meeting the evolving needs of modern industries.