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Abstract
A new coaxial plasma MIG welding system is developed for the purposes of improvement of weld bead, reduction of spatter and fume generation. Welding power sources of MIG and plasma, wire feeding equipment and a coaxial plasma MIG welding torch are described in detail. The metal transfer of plasma MIG welding in aluminium is observed and compared with that of pulsed MIG welding. Although one droplet per pulse is obtained by both processes, plasma MIG welding shows more smooth metal transfer than pulsed MIG welding. The result shows that spatter and fume generation are drastically reduced, and clean and good weld bead appearance is obtained by the new system.