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Numerical and experimental investigation of metal droplet transfer during pulsed bypass-current plasma-GMAW hybrid arc welding

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Abstract

In this research, AA 5083 aluminum alloy was proposed to be joined by the bypass-current plasma-GMAW hybrid arc welding with pulse current mode. During this hybrid process, three kinds of current work synergistically, including the main current from the welding wire, the bypass current into the copper nozzle, and the welding current into the base metal. Moreover, they have the same waveform due to the same system controlling them. For a deep understanding of the coupled effects of multiple pulse currents on metal droplets, a comprehensive study combining the experiment and the simulation was executed to compare the heat and mass transfer behaviors when the current mode changes. The results show that when the wire feed speed is maintained at 6 m/min, the droplets have a projected transfer mode no matter with which kind of current mode. However, the transfer frequency is increased by approximately double when the pulse waveform is employed. Furthermore, the transfer stability is further enhanced due to the force state getting regulated by the various hybrid electromagnetic fields stimulated by the pulse currents. This investigation offers a deeper understanding and continuous optimization of precise control of metal droplet behaviors in aluminum alloy welding.

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Funding

This research was supported by the National Natural Science Foundation of China (No. 51975138), High-Tech Ship Scientific Research Project from the Ministry of Industry and Information Technology ([2019]360), and High-Tech Ship Scientific Research Project from the Ministry of Industry and Information Technology (No. CJ05N20).

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Authors and Affiliations

  1. National Key Laboratory of Science and Technology on Underwater Vehicle, Harbin Engineering University, Harbin, 150001, China

    Ziran Wang, Yugang Miao, Ji Liu, Yuyang Zhao, Yifan Wu & Qingwen Deng

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  1. Ziran Wang
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  2. Yugang Miao
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  3. Ji Liu
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  4. Yuyang Zhao
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ZW and YM conceived the idea. ZW wrote the initial draft of the paper. All authors discussed the results and finalized this paper.

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Correspondence to Yugang Miao.

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Wang, Z., Miao, Y., Liu, J. et al. Numerical and experimental investigation of metal droplet transfer during pulsed bypass-current plasma-GMAW hybrid arc welding. Int J Adv Manuf Technol 129, 2747–2762 (2023). https://doi.org/10.1007/s00170-023-12487-7

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