Comparative analysis of manual GMAW and TWIN welding for energy-efficient manufacturing of disc mower cutterbars

Abstract

In the present study, welding processes used in the manufacturing of agricultural machinery were investigated with the aim of reducing manufacturing energy consumption, thermal deformation, and the carbon footprint associated with production. A comparative analysis was performed between manual gas metal arc welding (GMAW) and an automated twin-wire welding process (TWIN MIG PMC) for the fabrication of long cutterbars used in disc mowers. Experimental investigations included weld geometry characterization, microhardness measurements, finite element analysis of structural loads, and 3D scanning of technological deformations. The results show that the automated TWIN welding process significantly improves manufacturing efficiency and structural quality. Compared with manual welding, the TWIN process reduced welding time by approximately 61 %, electrical energy consumption by 32 %, and shielding gas consumption by 61 %. The lower heat input (≈31 % reduction) resulted in a smaller heat-affected zone and reduced technological deformation of the cutterbars by approximately 20 %, improving dimensional accuracy and eliminating the need for post-weld straightening operations. These results demonstrate that automated TWIN welding provides a more energy-efficient and dimensionally stable manufacturing solution for long welded structures used in agricultural machinery.