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Article

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Characteristics of Welding and Arc Pressure in the

2

Plasma–TIG Hybrid Welding Process

3

Bo Wang 1,2, Xunming Zhu 3, Hongchang Zhang 4,*, Hongtao Zhang 1,2,* and Jicai Feng 1

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1 State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001,

5

China; wangvbo@hit.edu.cn; zhanght@hitwh.edu.cn; fengjc@hit.edu.cn

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2 Shandong Institute of Shipbuilding Technology, Weihai 264209, China; wangvbo@hit.edu.cn;

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zhanght@hitwh.edu.cn

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3 Weihai Wanfeng Magnesium Sciecne and Technology Development Co.Ltd, Weihai 264209, China;

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xunming.zhu@wfjt.com

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4 Harbin University of Science and Technology Rongcheng Campus, Rongcheng, 264300, China;

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794230001@qq.com

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* Correspondence: zhanght@hitwh.edu.cn; Tel.: +86-187-6910-2227; 794230001@qq.com; Tel: +86-17863082611

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Abstract: In this article, a novel hybrid welding process called plasma-TIG coupled arc welding

15

was proposed to improve the efficiency and quality of welding by utilizing the full advantage of

16

plasma and TIG welding processes. The two arcs of plasma and TIG were pulled into each other

17

into one coupled arc under the effect of Lorentz force and plasma flow force during welding

18

experiments. The arc behavior of coupled arc was studied by means of it’s arc profile, arc pressure

19

and arc force conditions. The coupled arc pressure distribution measurements were performed.

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The effects of welding conditions on coupled arc pressure were evaluated and the maximum

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coupled arc pressure was improved compared with single-plasma arc and single-TIG arc. It was

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found that the maximum arc pressure was mainly determined by plasma arc current and plasma

23

gas flow. According to the results, the proposed coupled arc welding process have both advantages

24

of plasma arc and TIG method, and it has a broad application prospect.

25

Keywords: plasma-TIG; coupled arc; arc profile; pressure distribution

26

27

1. Introduction

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Given the continuous development of processing and manufacturing technologies, traditional

29

arc welding techniques, such as plasma arc welding (PAW)[1] and tungsten inert gas (TIG)[2,3]

30

welding process, have been improved to meet the requirements of enterprises for high-quality and

31

low-consumption welding technology[4]. In recent years, hybrid welding methods are proposed to

32

overcome these disadvantages and deficiencies. Hybrid welding methods have also been

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successfully applied in shipbuilding and spacecraft. Certain hybrid welding processes, including

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plasma–MIG[5,6], plasma–TIG[7,8], laser–GMAW[9], laser–TIG[10] and TIG–MIG[11], have been

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successfully used in the manufacturing industry. In comparison with ordinary single-arc welding,

36

hybrid welding technology can significantly improve welding efficiency and joint quality because it

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is simultaneously provided with multiple heat sources that complement one another[5].

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PAW produces arc plasma with high energy density and high arc pressure under the thermal

39

pinch effect of the water-cooled copper nozzle; thus, PAW has strong fusion and penetration

40

(2)

abilities[12,13]. However, identifying the appropriate parameters in PAW welding process is

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difficult and the process is prone to undercutting[14]. The gas tungsten arc welding with DCEN (

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Direct Current Electrode Negative Epolarity) is an high efficiency welding process[15,16], and has a

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good surface forming ability and remarkably stable welding process, but it’s penetration capacity is

44

poor. Therefore, researchers also proposed several hybrid welding processes that utilize the PAW

45

and TIG arcs, which mainly include the double-sided arc welding (DSAW) and PAW–TIG welding

46

processes[8]. The DSAW process can increase penetration and significantly improve welding

47

productivity[17], in this process, a TIG torch is placed on the opposite side of welds to guide the

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PAW arc into the keyhole, thereby permitting the current to flow from the PAW torch through the

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welds to the TIG torch directly instead of the conventional welding current loop[7,18]. However, the

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welding accessibility of DSAW is poor compared with PAW welding process. The PAW–TIG

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welding method is realized by the PAW and the subsequent TIG on the movable slide rail, no

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correlation exists between the plasma and TIG arcs. This process can also enhance the welding

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productivity. However, the heat-affected zone is large and the grain is coarse because the weld is

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reheated by the TIG arc. The plasma–TIG coupled arc welding (PTCAW) process is a novel hybrid

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welding method for overcoming the above deficiencies in order to achieve efficient welding process

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and high-quality welds.

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In this study, the PTCAW process was initially constructed and the coupled arc profile was then

58

analyzed by a charge-coupled device (CCD) camera. The effects of welding conditions on the

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coupled arc pressure distribution was also studied to reveal the characteristics of the coupled arc

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welding process The results provided the basis to recognize the PTCAW process and expanded the

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application range of PAW and TIG welding processes.

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2. Materials and Methods

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The schematic diagram of our experimental set-up is shown in Fig. 1. The PAW and TIG torches

64

were fixed on one fixture to realize the interaction between the two processes (i.e., PTCAW process).

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An experimental system was established according to the above designed principle. In the present

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system, the TIG arc was established by using a direct current–constant current (DC–CC) power

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supply (REHM InverTIG.Pro digital 240 AC/DC) under the direct current electrode negative(DCEN)

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condition. The PAW arcs were established by using an alternating current–direct current AC/DC

69

(LORCH V50 AC/DV) and DC–CC (LORCH Handy TIG 180 DC) power supplies. The Xiris

70

XVC-1000 weld camera (55 frames/s) was applied to observe and capture the arc profile and

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behavior under the different welding condition in real time[19]. The anode constricting nozzle of

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PAW made of red cooper with excellent thermal conductivity is cooled by forced recirculation

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cooling water to prevent the nozzle from being burned.

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Plasma gas

Shielding Gas Ar(99.99%)

PAW Torch

TIG Torch

Gas hood

Camera

Wire Feeder

5

5

150 Welding direction

67°

x

y

75

Fig. 1. Proposed PTCAW process system.

(3)

Differential pressure sensor (DPS: HSTL-FY01) was used to detect the arc pressure and pressure

77

distribution[20-22]. A 0.8-mm-diameter hole was drilled on a copperplate, which was fixed on

78

another water-cooled copperplate[23]. The details of the measurement system are shown in Fig. 2.

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Pressure Sensor Measurement Orifice Coupling Arc

Coupling Arc PAW Torch

TIG Torch

Water cooled Copper Block

+

+

— —

80

81

Fig. 2. Measurement system of the arc pressure.

82

In all experiments, the PAW torch nozzle has a 3-mm orifice diameter, 3.2-mm tungsten

83

diameter, and 3-mm tungsten setback. Pure argon (99.99%) was used as the plasma gas and

84

shielding gas. The platform diameter of the TIG terminal electrode is 1.25 mm, and the shielding gas

85

flow rate is 15 L/min. The electrode spacing is 7 mm, that is the distance from the plasma nozzle axis

86

to the electrode tip of TIG. The nozzle height is the distance from the end of PAW nozzle to the

87

workpiece surface. The detailed parameters for the designed experiments are shown in Table 2.

88

Table 2 Welding parameters for designed experiments.

89

3. Results and discussion

90

3. Results and Discussions

91

3.1. TPTCAW coupled arc profile

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A notable characteristic of the plasma-TIG welding method is the physical coupling effect

93

between the two arcs, which results in penetration increased and splash rate descended. The

94

detailed images of the plasma, TIG, and coupled arcs were acquired as shown in Figs.4. The RGB

95

images in the figure were transformed from gray images through pseudo-color processing in order

96

to acquire more detailed information of the arc profile. The base plate is made of red copper with

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forced recirculation cooling water and the welding experiment was carried out under the following

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conditions: a plasma welding current of 60A while TIG current of 100A, nozzle height of 5 mm and

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plasma gas flow of 15 L/min.

100

Figure 3 illustrates typical arc profile under different welding methods. Welding arcs is steady

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and plasma arc seems to be trumpet-shaped while TIG arc is similar to broom-shaped during single

102

arc welding because of the tungsten axis and the base plate have a 67 degrees angle, as shown in

103

Group Plasma arc

current (A)

TIG arc current (A) Nozzle height (mm) Plasma gas flow

(L/min)

#1 60, 80, 100, 120 100 5 4

#2 60 60, 90, 120, 150 5 4

#3 120 140, 160, 180, 200 5 4

#4 60 100 3, 4, 5, 6 4

(4)

Fig.3a & b. When the TIG arc is applied to plasma welding arc, it is observed that a novel coupled arc

104

is produced between the two arcs and the arc profile has a significant change from the previous. TIG

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arc can be deflected to plasma arc from the view of perpendicular to welding direction, and part of

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TIG arc is pushed to the side of plasma arc root, as shown in Fig.3c. At the same time, the coupled arc

107

profile seems to be bell-shaped similar to the conventional TIG arc from the view of parallel to the

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welding direction, as shown in Fig.3d.The reason for this behavior can be explained as follows.

109

110

Fig. 3. Arc profile under different welding methods. a single plasma arc. b single TIG arc. c coupled arc

111

perpendicular to the welding direction. d coupled arc parallel to the welding direction.

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Previous studies have suggested the forces play a major role in determining the arc profile[24].

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Therefore, it is necessary to analyze coupled arc force condition in order to explore the interaction

114

mechanism on coupled arc profile. It should be noted that the electromagnetic axial pressure and

115

plasma gas flow axial pressure are recognized as the key factor of PAW arc pressure[25]. The plasma

116

arc radius of arc column is r1, and the arc radius constricts to the minimum at the place of the arc

117

root, here is r2. The electromagnetic axial pressure on the arc axis can be expressed as the following

118

Eq. (1),

119

2 0

e 2 2 2

2 1

1

1

4

I

p

r

r

μ

π

=

(1)

Where µ0 = permeability of free space, I = plasma arc welding current. The plasma gas flow axis

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pressure towards to the molten pool surface can be expressed as the following Eq. (2).

121

2

g 1

1

2

p

=

ρμ

(2)

Where ρ = plasma gas density, µ1 = axial component of the plasma velocity. The plasma arc total pressure Pt

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on the arc axis can be expressed as the following Eq. (3).

123

2

2 0

t e g 2 2 2 1

2 1

1

1

1

4

2

I

p

p

p

r

r

μ

ρμ

π

=

+

=

+

(3)

Where Pe = electromagnetic axial pressure, and it is the function of I2.Pg = plasma gas flow axial

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pressure, and it is the function of ρ and µ1, simultaneously µ1 is the function of temperature. Hence,

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the resultant force on the arc axis from electrode tip to the surface of base plate can be expressed as

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the following Eq. (4).

127

2 2

2 2

0 1

r t 2 1 1

2

1

1

4

2

I

r

F

p S

r

r

μ

πρμ

π

= ⋅ =

− +

(4)

Where Fr = the plasma arc axis resultant force, S = the arc sectional area at the place of base

128

plate on the arc radial and S = πr12. Compared with the arc force condition during the single TIG

(5)

welding, the Lorentz force (FL) has a significant effect on TIG arc owing to plasma arc generates

130

additional magnetic field acts on the welding arc, and FL can be expressed as the following Eq. (5).

131

L

F

=

BIL

(5)

Where B = magnetic induction of magnetic field generated by plasma arc, L = displacement of

132

particle per unit. The schematic of the arc force condition as shown in Fig. 4. Considering the

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difference of arc force conditions on either side of TIG arc axis, it is necessary to specify four particles

134

(location A, B, C and D) as the research objects. On the side of the TIG arc, the plasma flow force is

135

considered as the main arc force of TIG welding arc, the plasma flow force can be expressed as the

136

following Eq. (6).

137

2

log(

b

)

P

a

R

F

KI

R

=

(6)

Where Ft = the plasma flow force of TIG arc at location B, C and D. K is a constant and K = µ/4π, µ =

138

medium magnetic conductivity, Ra and Rb are the radius of arc root surface and undersurface

139

respectively as shown in Fig. 5c.

140

As seen in Fig. 4 and Fig. 3c, the direction of plasma flow force (Fp2) on the arc axis can be

141

deflected to plasma arc at the location B, as shown in Fig. 5a. Furthermore, theplasma flow force acts

142

as the major driver force of the arc shift and has important influence on the weld surface forming.

143

According to right-hand grip rule at the location A, the direction of magnetic field generated by

144

plasma arc current is perpendicular to the paper inward on the side of TIG arc. Hence the particles

145

on the right side of plasma arc axis move towards plasma arc along the base plate under Lorentz

146

force (FL1 and FL2), the motion of TIG arc can be seen in Fig. 5a & c. At the same time, the plasma arc

147

is also deflected slightly towards the location B owing to the Lorentz force (FL3), as shown in Fig. 5 a

148

& b. In addition, part of particles of TIG arc have a potential of coupling with that of plasma arc root,

149

which result in transformation of TIG arc trajectory. These results indicate that the above analysis of

150

the coupled arc force conditions is consistent with the acquired experimental results in Fig. 3. It can

151

be concluded that the TIG arc is deflected under the combination effect of plasma flow force and

152

Lorentz force generated by the magnetic field of plasma arc column.

153

Plasma jet force

IP

IT

FL 3 IT

FL2

FP2

IT

Fr FP2

FL1

Welding current streamline FP1

FL 1

Workpiece

A B

C D

154

Fig. 4. Schematicof the forces acting on the coupled arcs

(6)

FL FL

PAW Arc TIG Arc

54.2°

63.6°

92.7°

90.0°

PAW Nozzle TIG Electrode

Ft

Ra

Rb

(a) (b) (c)

156

Fig. 5. Schematic of the behavior on the plasma arc Images of arc profile of different welding method. a

157

coupled arc welding. b plasma arc welding. c TIG arc.

158

Therefore, according to the aforementioned analysis, another interesting finding has caught our

159

attention. It is important to highlight that the coupling of two arcs and plasma flow force of arc are

160

proportional to the welding current, this phenomenon is in good consistent with Eq. (4) and Eq. (6). As can

161

be seen from Fig. 6, the coupled arc is generated only when the plasma arc current is bigger than 60A, at

162

the same time, the arc climbing height on plasma arc column increases with welding current (IP) when the

163

TIG welding current (IT) is constant at 100 amperes. However, as plasma arc current is constant at

164

60amperes, the plasma flow force (FP2) has a marked effect on welding arc profile acting on the base plate,

165

the heat transfer area of coupled arc acting on the workpiece is apparently increased with increase of

166

welding current (IT), as shown in Fig. 7.

167

(a) (b) (c) (d)

(e) (f) (g) (h)

168

Fig. 6. Acquired images of coupled arc profile with different TIG welding current. a 30A. b 40 A. c 50A. d

169

60 A. e 70 A. f 80 A. g 90 A. h 100A.

170

(a) (b) (c) (d)

(e) (f) (g) (h)

171

Fig. 7. Acquired images of coupled arc profile with different plasma welding current. a 40A. b 60 A. c 80A.

172

d 100 A. e 120 A. f 140 A. g 160 A. h 180A.

173

3.2 Arc pressure distribution of the coupled arc

174

The two-dimensional pressure distribution and pressure variation along with the welding

175

direction for each welding arc are shown in Fig. 8. The surface charts for individual stagnation

176

pressure of three welding method are drawn using Matlab® software in order to illustrate the

177

difference in magnitude between the values of arc pressure. According to the following

178

experimental results, there is another interesting finding that catches our attention. It is worthwhile

179

mentioning that the coupled arc pressure is mainly determined by plasma arc and proportion to the

180

welding current, and the welding conditions are listed in Table 3. The contour cloud image of the

(7)

coupled arc pressure distribution is shown in Fig. 8e, notably, it is similar to a gourd shape and the

182

maximum arc pressure appears between the two arcs near the side of plasma arc compared with

183

conventional plasma arc welding method. It can be seen that the maximum value of the coupled arc

184

is approximately 650 Pa and the maximum arc pressure decreased gradually with the increasing

185

electrode spacing, as shown in Fig. 9f. This result is significantly higher than that of plasma arc and

186

TIG arc under the same conditions, as shown in Fig. 9b & d. Therefore, it is indicated that the total

187

arc pressure of coupled arc depends on combination effect of these arcs, and it is consistent with the

188

above analysis of coupled arc profile.

189

Table 3 Experimental conditions for arc pressure measurement

190

191

-3 -2 -1 0 1 2 3

0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 A rc p res sur

e of T

IG

arc

(K

Pa

)

The distance to nozzle axis along with welding direction (mm) 0mm 0.5mm 1mm 1.5mm 2mm 2.5mm 3mm X-axis (mm) Y -ax is ( m m )

-3 -2 -1 0 1 2 3 -3 -2 -1 0 1 2 3 0.1 0.2 0.3 0.4 0.5 0.6 (c) (d)

-4 -3 -2 -1 0 1 2 3 4

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 A rc pre ssu re o f plas m a arc (K P a)

The distance to nozzle center axis along welding direction (mm) 0mm 0.5mm 1mm 1.5mm 2mm 2.5mm 3mm 3.5mm

(a) X-axis (mm) (b)

Y-axi

s

(mm)

-4 -3 -2 -1 0 1 2 3 4 -3.5 -2.5 -1.5 -0.5 0.5 1.5 2.5 3.5 0.1 0.2 0.3 0.4 0.5 0.6

-4 -3 -2 -1 0 1 2 3 4 5 6 7 8

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 A rc pre

ssure of the cou

pl

ed arc (KP

a)

The distance to nozzle axis along with welding direction (mm) 7mm 8mm 9mm 10mm X-axis(mm) Y-a xi s( mm)

-4 -3 -2 -1 0 1 2 3 4 5 -3.5 -2.5 -1.5 -0.5 0.5 1.5 2.5 3.5 0.1 0.2 0.3 0.4 0.5 0.6 (e) (f) 0 3.5 0

- 4 4

orifice

0 3

0

- 3 3

orifice

0.54

0.24

0.65

192

Fig. 8 Stagnation pressure distribution of welding arc with the different method. a top view of

193

two-dimensional distribution of the plasma arc. b the plasma arc pressure along with welding direction

194

with different distance to measurement orifice axis. c top view of two-dimensional distribution of the TIG

195

arc. d the TIG arc pressure along with welding direction with different distance to measurement orifice

196

axis. e top view of two-dimensional distribution of the coupled arc. f the coupled arc pressure along with

197

welding direction with different electrode spacing.

198

199

IP (A) IT (A) DPT (mm) L (mm) D (mm) Qp (L/min) Qs (L/min)

(8)

3.3 The influence factor of coupled arc pressure

200

Group #1 is the single-factor experiment to examine the effects of plasma current on the coupled

201

arc pressure distribution. The plasma arc as an important part of the coupled arc[26], the variation in

202

the current value has a significant influence on plasma flow force and mainly determines the

203

maximum arc pressure of the coupled arc. The histogram of the coupled arc pressure is acquired by

204

means of extracting the maximum value of distributed line type, as shown in Fig.9b.As can be seen

205

from part a and b of Fig. 9, the maximum arc pressure increases gradually with the rise in plasma

206

current and reaches 1600 Pa as plasma current is 120 amperes. In addition, according to the changes

207

of arc pressure curves at point a, it can be illustrated that the TIG arc pressure peak is overlapped

208

with that of plasma gradually with increase of plasma current, that is due to increase in Lorentz

209

force during the process. This result suggest that the coupling effect is strengthened between the two

210

arcs with the increase of plasma current.

211

-4 -3 -2 -1 0 1 2 3 4 5

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 A rc pr ess ure of coupl ed arc (K Pa)

Distance to nozzle axis along with welding direction (mm) 60A 80A 100A 120A

60 80 100 120

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 Th e m ix ium um va lue o f a rc pres sur e (KP a)

Different current of plasma arc (A)

(a) (b)

Point a

212

Fig. 9. Coupled arc pressure with different plasma current. a coupled arc pressure along with welding direction. b Max

213

value of coupled arc pressure.

214

Groups #2 and #3 are the single-factor experiments to examine the effect of TIG current on the

215

coupled arc pressure distribution. As previously mentioned, the change in TIG arc would has

216

different effects on the coupled arc pressure. It is necessary to analysis the arc pressure in two

217

situation, when the plasma arc current is 60 amperes, as shown in Fig. 10a, as the TIG current

218

increases, the maximum arc pressure of the coupled arc gets deviated to the side of TIG arc within a

219

small scale. This condition was mainly attributed to plasma flow force increases with welding

220

current, it results in an good TIG arc stiffness. On the contrary, when the plasma current increases to

221

120 amperes, as shown in Fig. 10b, the maximum arc pressure of the coupled arc gets deviated to

222

TIG arc by a large margin, the results indicate that the Lorentz force acting on plasma arc increases

223

enough to deflect the plasma as the TIG current increases. This is consistent with the observation

224

from the coupled arc profile.

225

-4 -3 -2 -1 0 1 2 3 4 5

0.0 0.2 0.4 0.6 0.8 Co up le d ar c pr essu re ( K P a)

Distance to nozzle axis along with welding direction (mm) 60A 90A 120A 150A

-4 -3 -2 -1 0 1 2 3 4 5 6

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 C oup le d ar c pre ssu re(K Pa)

Distance to nozzle axis along with welding direction (mm) 140A 160A 180A 200A (a) (b)

226

Fig. 10. Coupled arc pressure along with welding direction with different current

227

Group #4 is the single-factor experiment to examine the effect of the coupled arc length on the

228

coupled arc pressure distribution. The histogram of coupled arc along with the welding direction is

(9)

acquired by means of extracting the maximum value of distributed line type, as shown in Fig. 11b.

230

The maximum arc pressure initially decreased rapidly with the increase of nozzle height and then

231

plateaued; meanwhile, another interesting finding is that the coupled arc no longer decreases as the

232

nozzle height exceeds 5 mm. The results suggest that the horizontal component of the Lorentz force

233

and plasma flow force cancels each other and reach equilibrium state along with welding direction,

234

as shown in Eq. (5).

235

(a) (b)

-4 -3 -2 -1 0 1 2 3 4 5

0.0 0.2 0.4 0.6 0.8 A rc p ressu re o f co up le d a rc ( K Pa )

Distance to the nozzle axis along with welding direction (mm) 3mm 4mm 5mm 6mm

3 4 5 6

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 Th e ma xiu mum val ue of a rc pre ssu re ( KPa )

Different nozzle height (mm)

236

Fig. 11. Coupled arc pressure with different nozzle height. a coupled arc pressure along with welding direction. b Max

237

value of coupled arc pressure.

238

Group #5 is the single-factor experiment to examine the effect of plasma gas flow rates on the

239

coupled arc pressure distribution. Plasma gas flow rates (QP) has a significant effect on plasma

240

movement during welding process[27]. As shown in Fig. 12, the maximum arc pressure of the

241

coupled arc evidently increased with the increase of the plasma gas flow, it can be inferred that due

242

to increased plasma gas flow lead to the increase in axial component of plasma velocity and plasma

243

gas density, as shown in Eq. (2).

244

3 4 5 6

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 The m axium um val ue of the a rc pres sure (KPa)

Diferent plasma gas flow (L/min)

-4 -3 -2 -1 0 1 2 3 4 5

0.0 0.2 0.4 0.6 0.8 1.0 1.2 Ar c pr es sur e of the co uple d a rc ( KPa)

Distance to nozzle axis along with welding direction (mm) 3L/min 4L/min 5L/min 6L/min (a) (b)

245

Fig. 12. Coupled arc pressure with different plasma gas flow. a coupled arc pressure along with welding direction. b Max

246

value of coupled arc pressure.

247

4. Conclusions

248

From the current study, a novel hybrid welding method has been proposed, and the coupled

249

arc behavior has been explored. The coupled arc profile and coupled arc pressure have been

250

considered as ascertaining the mechanics circumstance of coupled arc behavior. The following

251

conclusions could be obtained:

252

1. Under the function of Lorentz force and plasma flow force, TIG arc is deflected and couples

253

with plasma arc, a coupled arc is generated and involves at once the arc characteristics of

254

plasma and TIG.

(10)

2. The coupled arc profile is mainly determined by the combination effect of plasma flow force

256

and Lorentz force generated by the magnetic field of plasma arc column, which is affected

257

by the welding current from plasma and TIG.

258

3. The coupled arc pressure distribution in two-dimensional surface is similar to gourd shape,

259

the maximum arc pressure appears between plasma arc and TIG arc and it is mainly

260

determined by the plasma current. The welding conditions that affect the coupled arc

261

distribution and the maximum pressure could be ranked according to their effects on the

262

experimental results, namely, plasma current, plasma gas flow, TIG current and electrode

263

spacing.

264

Author Contributions: Hongtao Zhang and Bo Wang conceived and designed the experiment; Hongchang

265

Zhang perform the experiments; Bo Wang analysed the data and wrote the article; Xunming zhu and Jicai Feng

266

contributed to the data analysis and discussion.

267

Acknowledgments: The research was sponsored by Shandong Provincial Natural Science Foundation

268

(ZR201709200029), Shandong Key research and development plan (2017GGX30132), Shandong Key research

269

and development plan (GG201709250277), Natural Scientific Reasearch Foundation in Harbin Institute of

270

Technology (HIT.NSRIF.201707) and Young Taishan Scholars Program of Shandong Province (tsqn20161062) .

271

Conflicts of Interest: The authors declare no conflict of interest.

272

References

273

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Liu, Z.M.; Cui, S.; Luo, Z.; Zhang, C.; Wang, Z.; Zhang, Y. Plasma arc welding:

274

Process variants and its recent developments of sensing, controlling and modeling.

275

Journal of Manufacturing Processes

2016,

23

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Figure

Fig. 1. Proposed PTCAW process system.
Fig. 2. Measurement system of the arc pressure.
Fig.3a & b. When the TIG arc is applied to plasma welding arc, it is observed that a novel coupled arc is produced between the two arcs and the arc profile has a significant change from the previous
Fig. 4. Schematic of the forces acting on the coupled arcs
+5

References

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