Experimental Study on Wire Melting Control Ability of Twin-Body Plasma Arc

The twin-body plasma arc has the decoupling control ability of heat transfer and mass transfer,which is beneficial to shape and property control in wire arc additive manufacturing.In this paper,with the wire feeding speed as a characteristic quantity,the wire melting control ability of twin-body plasma arc was studied by adjusting the current separation ratio(under the condition of a constant total current),the wire current/main current and the position of the wire in the arc axial direction.The results showed that under the premise that the total current remains unchanged(100 A),as the current separation ratio increased,the middle and minimum melting amounts increased approximately synchronously under the effect of anode effect power,the first melting mass range remained constant;the maximum melting amount increased twice as fast as the middle melting amount under the effect of the wire feeding speed,and the second melting mass range was expanded.When the wire current increased,the anode effect power and the plasma arc power were both factors causing the increase in the wire melting amount;however,when the main current increased,the plasma arc power was the only factor causing the increase in the wire melting amount.The average wire melting increment caused by the anode effect power was approximately 2.7 times that caused by the plasma arc power.The minimum melting amount was not affected by the wire-torch distance under any current separation ratio tested.When the current separation ratio increased and reached a threshold,the middle melting amount remained constant with increasing wire-torch distance.When the current separation ratio continued to increase and reached the next threshold,the maximum melting amount remained constant with the increasing wire-torch distance.The effect of the wire-torch distance on the wire melting amount reduced with the increase in the current separation ratio.Through this study,the decoupling mechanism and ability of this innovative arc heat source is more clearly.

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.

OES study of the gas phase during diamond films deposition in high power DC arc plasma jet CVD system

This paper used optical emission spectroscopy （OES） to study the gas phase in high power DC arc plasma jet chemical vapour deposition （CVD） during diamond films growth processes. The results show that all the deposition parameters （methane concentration, substrate temperature, gas flow rate and ratio of H2/Ar） could strongly influence the gas phase. C2 is found to be the most sensitive radical to deposition parameters among the radicals in gas phase. Spatially resolved OES implies that a relative high concentration of atomic H exists near the substrate surface, which is beneficial for diamond film growth. The relatively high concentrations of C2 and CH are correlated with high deposition rate of diamond. In our high deposition rate system, C2 is presumed to be the main growth radical, and CH is also believed to contribute the diamond deposition.

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.

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.

A New Waste Disposal Technology-plasma arc Pyrolysis System

This paper introduces a new waste disposal technology with plasma arc. Being different from conventional combustion or burning such as incineration, it is based on a process called controlled pyrolysis-thermal destruction and recovery process. It has four advantages, they are completely safe, clean, high-energy synthesis gas, non-toxic vitrified slag and metal.

Effect of Ti-Si-Mg-Al wire on microstructure and mechanical properties of plasma arc in-situ welded joint of SiC_p/Al composites

The influence of Ti-Si-Mg-AI wire on microstructure and mechanical properties of SiCp/A1 metal matrix composite joints produced by plasma arc in-situ weld-alloying was investigated. Argon-nitrogen mixture was used as plasma gas and Ti-Si-Mg-A1 flux-cored wires as filled composites. Weldments were submitted to tensile test. Meanwhile, the macro morphology and microstructure of the joints were examined. The result shows that the formation ofneedie-like harmful phase A14C3 is effectively inhibited and the wettability of molten pool is improved by adding Ti-Si-Mg-A1 flux-cored wires. With 15Ti-5Si-5Mg-A1 flux-cored wire as filled composite, the maximum tensile strength of the welded joint is 267 MPa, which is up to 83% that of the matrix composites under annealed condition.

Effect of arc-ultrasound on microstructures and mechanical properties of plasma arc welded joints of SiC_p/Al MMCs

The effect of arc-ultrasound on microstructures and mechanical properties of SiCp/6061A1 MMCs joints produced by arc-ultrasound plasma arc ＂in-situ＂ alloy-welding with different excitation frequencies was investigated, in which argon-nitrogen mixture was used as plasma gas, Ti wire as filler and the arc-ultrasound was produced by modulating the plasma arc with high frequency. The results show that arc-ultrasound could refine the new reinforced composites such as TiC, TiN significantly, and improve their distribution greatly. And new phase A13Ti becomes finer and less. The test results of mechanical properties indicate that the maximum tensile strength of welded joints is gained when the excitation frequency is 50 kHz, and the maximum is 225 MPa, raising by about 7% comoared with conventional nlasma arc welding （PAW） （20q MPa）.

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.

Characterization of carbon encapsulated Fe-nanoparticles prepared by confined arc plasma

Carbon encapsulated Fe nanoparticles were successfully prepared via confined arc plasma method. The composition, morphology, microstructure, specific surface area and particle size of the product were characterized via X-ray diffraction, transmission electron microscopy, high resolution transmission electron microscopy, energy dispersive X-ray spectrometry and Brunauer-Emmett-Teller N2 adsorption. The experiment results show that the carbon encapsulated Fe nanoparticles have clear core-shell structure. The core of the particles is body centered cubic Fe, and the shell is disorder carbons. The particles are in spherical or ellipsoidal shapes. The particle size of the nanocapsules ranges from 15 to 40 nm, with the average value of about 30 nm. The particle diameter of the core is 18 nm, the thickness of the shells is 6-8 nm, and the specific surface area is 24 m2/g.

Hydrogen storage properties of Mg-TiO_2 composite powder prepared by arc plasma method

Mg-based Mg-TiO2 composite powder was prepared by arc plasma evaporation of the Mg＋5%TiO2 mixture followed by passivation in air. ICP, XRD and SEM techniques were used to characterize the composition, phase components and microstructure of the composite powder. The hydrogen sorption properties of the composite powder were investigated by DSC and PCT techniques. According to the data from PCT measurements, the hydrogenation enthalpy and entropy changes of the composite powder are calculated to be-71.5 kJ/mol and-130.1 J/（K·mol）, respectively. Besides, the hydrogenation activation energy is determined to be 77.2 kJ/ mol. The results indicate that TiO2 added into Mg by arc plasma method can act as a catalyst to improve the hydrogen sorption kinetic properties of Mg.

Numerical Study on Arc Plasma Behavior During Arc Commutation Process in Direct Current Circuit Breaker

This paper focuses on the numerical investigation of arc plasma behavior during arc commutation process in a medium-voltage direct current circuit breaker （DCCB） contact system. A three-dimensional magneto-hydrodynamic （MHD） model of air arc plasma in the contact system of a DCCB is developed, based on commercial software FLUENT. Coupled electromagnetic and gas dynamic interactions are considered as usual, and a thin layer of nonlinear electrical resistance elements is used to represent the voltage drop of plasma sheath and the formation of new arc root. The distributions of pressure, temperature, gas flow and current density of arc plasma in arc region are calculated. The simulation results indicate that the pressure distribution related to the contact system has a strong effect on the arc commutation process, arising from the change of electrical conductivity in the arc root region. In DCCB contact system, the pressure of arc root region will be concentrated and higher if the space above the moving contact is enclosed, which is not good for arc root commutation. However, when the region is opened, the pressure distribution would be lower and more evenly, which is favorable for the arc root commutation.

Numerical analysis of plasma arc physical characteristics under additional constraint of keyhole

The physical characteristics of a plasma arc affect the stability of the keyhole and weld pool directly during keyhole plasma arc welding(KPAW).There will be significant change for these characteristics because of the interaction between the keyhole weld pool and plasma arc after penetration.Therefore,in order to obtain the temperature field,flow field,and arc pressure of a plasma arc under the reaction of the keyhole,the physical model of a plasma arc with a pre-set keyhole was established.In addition,the tungsten and base metal were established into the calculated domain,which can reflect the effect of plasma arc to weld pool further.Based on magneto hydrodynamics and Maxwell equations,a twoSdimensional steady state mathematical model was established.Considering the heat production of anode and cathode,the distribution of temperature field,flow field,welding current density,and plasma arc pressure were solved out by the finite difference method.From the calculated results,it is found that the plasma arc was compressed a second time by the keyhole.This additional constraint results in an obvious rise of the plasma arc pressure and flow velocity at the minimum diameter place of the keyhole,while the temperature field is impacted slightly.Finally,the observational and metallographic experiments are conducted,and the shapes of plasma arc and fusion line agree with the simulated results generally.

APPLICATION OF ARTIFICIAL NEURAL NETWORK MODELING TO PLASMA ARC WELDING OF ALUMINUM ALLOYS

By using alternating current plasma arc welding,the influences were studied of such parameters as welding curent,arc voltage,welding speed,wire feed rate,and magnitude of ion gas flow on front melting width,wdle reinforcement,and back melting width of LF6 aluminum alloy.Model of the formation of welding seam in alternating current plasma arc welding of aluminum was set up with the method of artificial neural neural network - BP algorithm. Qyakuty of formation was consequently predicted and evaluated.The experimental result shows that,compared with other modeling methods,artificial network model can be used to more accurately predict formation of weld,and to guide the production practice.

Parameter optimization for tungsten carbide/Ni-based composite coating deposited by plasma transferred arc hardfacing

Ni-based composite coatings with a high content of tungsten carbides(Stelcar65composite coatings)were synthesized by plasma transferred arc(PTA)hardfacing.The welding parameters of Stelcar65composite coatings were optimized by orthogonal tests.The PTA welding parameters including welding current,powder feed rate and welding speed have significant influence on the tungsten carbide degradation.The values for the optimum welding current,powder feed rate and welding speed were determined to be100A,25g/min and40mm/min,respectively.The produced WC/Ni-based composite coatings were crack-and degradation-free.The microstructure of deposited layers,as well as the microstructure and microhardness of the optimal coating were further analyzed.

STUDY ON THE PRESSURE IN PLASMA ARC

The axial pressure in plasma arc is measured under different conditions. Theeffects of the parameters, such as welding current, plasma gas flow rate, electrode setback and arclength, on the pressure in plasma arc are investigated and quantitative analyzed to explain therelationship between the quality of weld and the matching of parameters in plasma arc weldingprocess.

Effects of Y_2O_3 on the microstructure and wear resistance of cobalt-based alloy coatings deposited by plasma transferred arc process

Cobalt-based alloys with different Y2O3 contents were deposited on Q235A-carbon steel using plasma transferred arc （PTA） welding machine. The effect of Y2O3 on the microstructure and wear resistance properties of the cobait-based alloys were investigated using an optical microscope, a scanning electron microscope （SEM）, X-ray diffraction （XRD）, and transmission electron microscopy （TEM）. It was found that a cobalt-based solid solution with a face-centered cubic crystal structure was presented accompanied by the secondary phase M7C3 with a hexagonal crystal structure in the Y2O3-free cobalt-based alloy coating. Several stacking faults exist in the cobalt-based solid solution. The addition of Y2O3 leads to the existence of the Y2O3 phase in the Y2O3-modified coatings. Though stacking fault exists in the Y2O3-modified coatings, its density increases. The addition of Y2O3 can refine the microstructure and can increase the wear resistance properties when its contents are less than or equal to 0.8 wt.%. However, further increase of its contents will lead to the agglomeration of undissolved Y2O3 particles at the γ-Co grain boundary, and will lead to a coarse microstructure and lower wear resistance properties.

Characteristics of arc in variable polarity plasma arc welding of aluminum alloy

A double invert variable polarity plasma arc （VPPA） power source based on 16-bit MCU applied for aluminum alloys was developed. Mechanics, electrical and the produced heat mechanism of VPPAW arc were tested and analyzed. Results indicate that during the VPPA welding procedure of aluminum alloy, the arc of electrode negative （EN） has more effect on force, whereas the arc of electrode positive （ EP ） has more effect on heat. It should be noted that keeping the balance of the force and heat is the critical element of VPPAW. This power source had been successfully used to weld aluminum alloy with a 15 mm thickness in vertical welding. The conclusions are applicable to the variable polarity plasma arc welding technique used in the aerospace industry.

Investigation on Plasma Jet Flow Phenomena During DC Air Arc Motion in Bridge-Type Contacts

Arc plasma jet flow in the air was investigated under a bridge-type contacts in a DC 270 V resistive circuit. We characterized the arc plasma jet flow appearance at different currents by using high-speed photography, and two polished contacts were used to search for the relationship between roughness and plasma jet flow. Then, to make the nature of arc plasma jet flow phenomena clear, a simplified model based on magnetohydrodynamic （MHD） theory was established and calculated. The simulated DC arc plasma was presented with the temperature distribution and the current density distribution. Furthermore, the calculated arc flow velocity field showed that the circular vortex was an embodiment of the arc plasma jet flow progress. The combined action of volume force and contact surface was the main reason of the arc jet flow.

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.