Welding of Ti-6Al-4V alloy using dynamically controlled plasma arc welding process

A novel dynamically controlled plasma arc welding process was introduced,which is able tominimize heat input into the workpiece materials while maintaining desired full penetration,and it was used to weld Ti-6Al-4V alloy sheets.The microstructures,facture surfaces and microhardness of the welded joints were characterized by using optical microscope,scanning electron microscope （SEM） and Vickers microhardness tester.Comparing with welds such as gas tungsten arc and conventional plasma arc processes,the experimental results revealed the improvements when using the present process including：1） reducing prior-beta （β） grain size and prohibiting formation of hard martensite phases in the fusion zone due to the decreased heat input;and 2） better toughness and higher hardness.

RELATIONSHIP BETWEEN PLASMA OPTIC SIGNAL AND PENETRATION DEPTH FOR PARTIAL-PENETRATION LASER WELDING

Through sampling and analyzing of plasma optic signals of 400-600 nm emitted from partial-penetration laser welding processes, how the penetration depth is related to the welding parameter and the plasma optic signal is studied, Under the experimental conditions, the plasma optic signal has good response to variety of the weld penetration, and the signal＇s RMS value increases with the penetration in a quadratic curve mode. The inherent relation between the plasma optic signal and the penetration depth is also analyzed. It is also found that, between the two common parameters of laser power and welding speed, laser power has more influence on penetration while welding speed has more influence on weld width. The research results provide theoretic and practical bases for penetration real-time monitoring or predicting in partial-penetration laser welding,

Droplet transition for plasma-MIG welding on aluminium alloys

The synchronous acquisition system of droplet image inspection and arc electric signals were established and the droplet transition characteristics of aluminum alloys were researched in the plasma-MIG welding process.Typical droplet transition modes include globular transfer mode,short circuiting transfer mode,metastable spray transfer mode and projected transfer mode.The result indicates that MIG droplet transfer frequency and droplet transfer modes are changed by introducing the plasma arc in the plasma-MIG welding process compared with the MIG welding on the aluminum alloys,which broadens the range of welding parameters when the stable welding process proceeds.The metastable spray transfer and projected transfer mode are proved to be the most optimal modes by comparing the stability of electronic signal,droplet transition,weld appearance and weld penetration.

Preparation of Ni60-WC Coating by Plasma Spraying, Plasma Re-melting and Plasma Spray Welding on Surface of Hot Forging Die

In order to produce the hear-resistant inner layer of hot-forging die, the plasma spraying and plasma re-melting and plasma spray welding were adopted. Substrate material was W6Mo5Cr4V2, including 10%, 20%, 30% tungsten carbide （WC） ceramic powder used as coating material to obtain different Nickel-based WC alloys coating. Micro-structure and micro-hardness analysis of the coating layer are conducted, as well as thermophysical properties for the coating layer were measured. The experimental results show that the coating prepared with 70%Ni60, 30%WC powder has the best properties with plasma spray welding, in which the micro-hardness can achieve 900HV, meanwhile it can improve the thermal property of hot-forging die dramatically.

Finite element analysis of keyhole plasma arc welding based on an adaptive heat source mode

An adaptive heat source mode is proposed to account for the keyhole effect and the characteristics of volumetric distribution along the direction of the workpiece thickness. Finite element analysis of the temperature field in keyhole plasma arc welding is conducted and the weld geometry is obtained. The predicted results are in agreement with the measured ones.

Ni60-SiC Coating Prepared by Plasma Spraying, Plasma Re-melting and Plasma Spray Welding on Surface of Hot Forging Die

In order to produce the hear-resistant inner layer of hot-forging die, plasma spraying and plasma re-melting and plasma spray welding were adopted. Substrate material was W6Mo5Cr4V2, including 10%, 20%, 30% SiC ceramic powder used as coating material to obtain different Ni-based SiC alloys coating. Micro-structure and micro-hardness analysis of the coating layer were followed, as well as thermophysical properties for the coating layer were measured. The experimental results show that the coating prepared with 70% Ni60, 30% SiC powder has best properties with plasma spray welding, in which the micro-hardness can achieve 1100 HV, meanwhile can improve the thermal property of hot-forging die dramatically.

Modeling the keyhole shape and dimension in plasma arc welding

It is of great significance to model the keyhole shape and dimensions to optimize the plasma arc welding process parameters. In this study, through employing a combined volumetric heat source mode, the weld pool in keyhole plasma arc welding is determined firstly, and then the dynamic force-balance condition on the interface between the plasma jet and the molten metal is dealt with in describing the keyhole formation inside the weld pool. The effects of welding current on the shape and size of keyhole are numerically analyzed. The sharp transformation from a partial keyhole to a full-penetration keyhole is quantitatively demonstrated.

A computer-based control system for keyhole plasma arc welding

A new kind of control system for keyhole plasma arc welding （K-PAW） was developed based on the computer and the Graphics Language--LabVIEW. It can set and output the required current waveforms with desired decreasing slopes so that the corresponding ＂opening and closing＂ of keyhole can occur periodically. With this control strategy of welding current waveforms, the workpiece is fully penetrated while no burn-through Occurs. Keyhole plasma arc welding experiments were conducted to verify the stability and reliability of the developed system.

Experimental determination of the weld penetration evolution in keyhole plasma arc welding

Keyhole plasma arc welding experiments are conducted to measure the weld geometry and penetration at different moments during the initial phase from igniting arc to quasi-steady state. Indirect information on keyhole formation and evolution in plasma arc welding can be extracted based on the weld macrophotograph at cross section. It has laid foundation to verify the mathematical models of keyhole plasma arc welding.

Determination of arc pressure pool surface in and current density on the molten plasma arc welding

A unified numerical model is developed to couple the plasma arc, weld pool and keyhole in a self consistent way. The plasma arc/anode interface and the melt/solid interface are treated specially, the VOF method is used to trace the moving keyhole wall, and the fluid flow and heat transfer in both the plasma arc and weld pool are numerically simulated. The distributions of current density and arc pressure on the weld pool surface during the keyhole formation process are analyzed using the coupled model. The predicted arc pressure and current density are compared with the experimentally measured results, and both are in good agreement.

Analysis of keyhole geometry in plasma arc welding

The key problem for numerical simulation of plasma arc welding （PAW） process is to develop a suitable and adaptive volumetric heat source mode which reflects the physical characteristics of keyhole PAW. To this end, the keyhole geometry under different PAW process conditions must be predicted. In this paper, a mathematical model for determining the keyhole shape is developed with considering the mass and momentum conservation of the in-keyhole plasma jet as well as the pressure equilibrium at the plasma jet/liquid metal boundary. A suitable heat source model related to the keyhole shape is applied to the calculation of PAW weld dimensions. The predicted results are in good agreement with the experimental ones.

Characterization of microstructure and strain response in Ti-6Al-4V plasma welding deposited material by combined EBSD and in-situ tensile test

Additive layer manufacturing （ALM） of aerospace grade titanium components shows great promise in supplying a cost-effective alternative to the conventional production routes. Complex microstructures comprised of columnar remnants of directionally solidifiedβ-grains, with interior inhabited by colonies of finerα-plate structures, were found in samples produced by layered plasma welding of Ti-6Al-4V alloy. The application of in-situ tensile tests combined with rapid offline electron backscatter diffraction （EBSD） analysis provides a powerful tool for understanding and drawing qualitative correlations between microstructural features and deformation characteristics. Non-uniform deformation occurs due to a strong variation in strain response between colonies and across columnar grain boundaries. Prismatic and basal slip systems are active, with the prismatic systems contributing to the most severe deformation through coarse and widely spaced slip lines. Certain colonies behave as microstructural units, with easy slip transmission across the entire colony. Other regions exhibit significant deformation mismatch, with local build-up of strain gradients and stress concentration. The segmentation occurs due to the growth morphology and variant constraints imposed by the columnar solidification structures through orientation relationships, interface alignment and preferred growth directions. Tensile tests perpendicular to columnar structures reveal deformation localization at columnar grain boundaries. In this work connections are made between the theoretical macro- and microstructural growth mechanisms and the observed microstructure of the Ti-6Al-4V alloy, which in turn is linked to observations during in-situ tensile tests.

Analysis of the 3-D fluid velocity and temperature profile in keyhole plasma arc welding

Modeling and simulation of fluid flow and heat transfer in keyhole plasma arc welding is of great significance for optimizing the process parameters. In this study, a three-dimensional transient model is established to analyze numerically the heat transfer and fluid flow phenomena in keyhole plasma arc welding. VOF （volume of fluid） method is used to track the boundary of the keyhole. The dynamic developments of keyhole geometry, the fluid velocity field and temperature profiles are numerically simulated. And the changing Of the fluid velocity and pressure distribution on the keyhole wall in the forming process of the keyhole are analyzed.

System Identification of Controlled Pulse Keyhole Plasma Arc Welding Process

The development of closed-loop control systems is one of the most effective ways to improve the stability of the keyhole status during keyhole plasma arc welding （K-PAW）. Due to the disadvantages of the ＂one-pulse-one-keyhole＂ technology based on the conventional square current waveform, the controlled pulse welding current waveform is newly applied to control the keyhole open and close periodically. In order to realize the real-time control on the keyhole behavior with this advanced current waveform, welding experiments and system identification are conducted based on the classical control theory. One complete welding cycle can be divided into 3 periods. The keyhole establishing time is the most important time variable, which determines the keyhole behavior and welding process stability. At the same time, the averaged effiux plasma arc voltage during one pulse cycle can reflect the real keyhole dimension and status in a real-time manner. Therefore, two single-input-single-output （SISO） systems are proposed, in which keyhole establishing time and keyhole average dimension are taken as the system controlled variables respectively. Welding experiments are designed with the peak current varying randomly. Experiments show that the keyhole establishing time changes in an opposite direction to the varied peak current, and the averaged efflux plasma arc voltage varies with the same trend as the peak current. Based on the least squares technique and F test of classical system identification, second order difference equation for keyhole establishing time/peak current system and first order difference equation for keyhole average dimension/peak current system are obtained. It is proved that the calculated data by the two mathematical expressions are well matched with the measured data. The proposed research provides mathematical expressions and theoretical analysis to develop closed-loop systems for the controlled pulse K-PAW.

Modeling of Arc Force in Plasma Arc Welding

A three-dimensional mathematical model for the transferred-type argon arc was developed to describe arc force on the anode surface. The software ANSYS was employed to solve the model. The model includes a part of torch and tungsten electrode to achieve more reasonable resuits. The arc temperature and flow fields were derived. And the influences of welding parameters on arc force were also studied. The simulated results show that arc pressure at the anode are dependent on the welding current, plasma gas flow rate and electrode neck-in, while not sensitive to arc length.

NTWV-based sensing keyhole dimension in plasma arc welding

During stable keyhole plasma arc welding, the pilot arc and the transferred arc exist at the meantime, and the arcs can be considered as a composition of two parts inside and outside the nozzle, respectively. Under the mechanical constriction and thermal contraction effects, the inside arc has certain arc length, electron density and arc profile etc. inducing constant tungsten-to-nozzle voltage. However, the arc outside the nozzle diverges at about 5 degrees and has certain characteristics similar to the free arcs. The nozzle-to-workpiece voltage （NTWV） depends mainly on the length of the arc, which gets bigger as increasing of the weld penetration and keyhole size. The NTWV sensor is developed for monitoring NTWV in real time. The welding experiments are designed to get different penetrations and keyhole sizes. It is found that as the weld penetration and the keyhole size increase, NTWV also increases linearly. The NTWV signals can be used as the feedback variable in automatic control of keyhole plasma arc welding.

Closed-loop control system design and experimental study for controlled pulse keyhole plasma arc welding

The controlled pulse waveform is newly applied in keyhole plasma arc welding process. Two additional descending slopes can guarantee stable and smooth transition of keyhole closing and opening periodically. To develop a closed-loop control system for this special welding process, the key point is the determination of system input and output variables. The averaged efflux plasma voltage during a pulse cycle is defined as the characteristic variable reflecting the real keyhole dimension. Research and experiments are conducted to explore the relationship between the characteristic variable and weld pe^Cormance. Results show that alternated peak current can significantly change the keyhole dimension and the penetration. It is proposed that the keyhole average dimension is taken as the controlled variable, and the peak pulse current value and slopes are taken as control variables.

Numerical analysis of transient keyhole shape in pulsed current plasma arc welding

Based on the characteristics of ＂one keyhole in a pulse＂ in pulsed current plasma arc welding （PAW） , the transient variation process of weld pool in a pulse cycle is simulated through the establishment of corresponding heat source model. And considering the effects of gravitational force, plasma arc pressure and surface tension on the weld pool surface, the dynamic change features of the keyhole shape in a pulse cycle are calculated by using surface deformation equation. Experiments are conducted and validate that the calctdated weld fusion line is in good agreement with the experimental results.

Numerical analysis of weld pool geometry in pulsed current plasma arc welding

Numerical analysis of weld pool shape and size is of great significance for selection and optimization of the process parameters in pulsed current plasma arc welding （PAW）. In this paper, a mathematical model and relevant algorithm are developed to determine the temperature profiles and weld pool geometry in pulsed current PAW through employing an adaptive heat source model. The volumetric heat source consists of semi-ellipsoid at upper part and a conic body at lower part along the workpiece thickness direction. The dynamic variation features of weld pool shape during a pulse cycle are numerically simulated. The calculated weld cross-section is consistent with the measure one.

Simultaneous observation of keyhole and weld pool in plasma arc welding with a single cost-effective sensor

The dynamic behaviors of the keyhole and weld pool are coupled together in plasma arc welding, and the geometric variations of both the keyhole and the weld pool determine the weld quality. It is of great significance to simultaneously sense and monitor the keyhole and the weld pool behaviors by using a single low-cost vision sensor in plasma arc welding process. In this study, the keyhole and weld pool were observed and measured under different levels of welding current by using the near infrared sensing technology and the charge coupled device （CCD） sensing system. The shapes and relative position of weld pool and keyhole under different conditions were compared and analyzed. The observation results lay solid foundation for controlling weld quality and understanding the underlying process mechanisms.