Effects of bypass-current and out plasma current on droplet transfer behaviours during plasma-MIG hybrid arc welding

Abstract

A new method, bypass-current plasma-MIG hybrid arc welding, was proposed to weld AA 5083 aluminium alloy. A comparative investigation between simulation and experiment was performed to quantify different effects of bypass-current and out plasma current on droplet transfer behaviours. The results show that when the bypass-current is 15 A, the droplets present a projected transfer mode, and its period is 22 ms. But if the outer plasma current is 15 A, the transfer frequency increases 19.1 Hz, and the sizes of the droplet show a slight increase. This is due to the reduction of electromagnetic force and arc plasma force on droplets. The research outcomes provide benefits to the droplet transfer behaviours in control and optimisation during aluminium alloy welding.

KEYWORDS:

• Bypass-current plasma-MIG hybrid arc
• simulation
• aluminium alloy
• droplets transfer behaviours

Acknowledgement

The authors would like to thank the anonymous reviewers and editor.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

This research was sponsored by the National Natural Science Foundation of China [grant number 51975138], High-Tech Ship Scientific Research Project from the Ministry of Industry and Information Technology [grant number [2019]360], [grant number CJ05N20].