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

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.

Automated summary

A new method of bypass-current plasma-MIG hybrid arc welding for AA 5083 aluminium alloy was proposed, and a comparative investigation between simulation and experiment was conducted to quantify the effects of bypass-current and out plasma current on droplet transfer behaviours. The results indicate that the variation of bypass-current and out plasma current can lead to changes in droplet transfer mode and frequency, which is significant for controlling and optimizing the welding process of aluminium alloy.