This study investigated the influence of technological parameters of plasma arc welding using a bipolar asymmetric current with a rectangular waveform on weld-pool formation in Al–Mg–Mn alloys, using alloy 1560 containing 6% magnesium as the primary alloying element as the model material. This work established the relative significance of these parameters in governing weld penetration depth. It has been determined that, in addition to the well-known welding parameters (current amplitude and welding speed), weld formation during plasma arc welding with an asymmetric current of reverse polarity is also affected by the frequency of the asymmetric variable-polarity current, the duration of current flow in straight polarity (balance), and the flow rate of the plasma gas. Increasing the plasma gas flow rate (at constant current amplitude, plasma-nozzle orifice diameter, asymmetric variable-polarity current frequency, and balance) leads to an increase in plasma arc voltage of up to 18%, as well as to a corresponding increase in penetration depth. As the frequency of the asymmetric variable-polarity current increases from 50 to 200 Hz, the penetration depth increases by more than a factor of two. Shifting the polarity balance of the asymmetric variable-polarity current toward reverse polarity (from 85% to 50% straight polarity) results in an increase in the average plasma arc voltage, leading to an increase in weld width and an approximately twofold decrease in penetration depth. The use of pure helium as a shielding gas in plasma arc welding with variable-polarity current of aluminum alloys increases the penetration depth by 45%–90% compared with pure argon. Overall, variations in process parameters during plasma arc welding with asymmetric variable-polarity current exert a significantly stronger influence on weld penetration depth than on weld width.
Citation: Volodymyr Korzhyk, Andrii Grynyuk, Yunqiang Zhao, Oleksandr Bushma, Oksana Konoreva, Oleksandr Voitenko, Guirong, Zhe Liu. Influence of plasma arc characteristics on penetration depth and weld formation during welding of Al-Mg-Mn alloy with asymmetric variable polarity current[J]. AIMS Materials Science, 2025, 12(6): 1265-1295. doi: 10.3934/matersci.2025059
This study investigated the influence of technological parameters of plasma arc welding using a bipolar asymmetric current with a rectangular waveform on weld-pool formation in Al–Mg–Mn alloys, using alloy 1560 containing 6% magnesium as the primary alloying element as the model material. This work established the relative significance of these parameters in governing weld penetration depth. It has been determined that, in addition to the well-known welding parameters (current amplitude and welding speed), weld formation during plasma arc welding with an asymmetric current of reverse polarity is also affected by the frequency of the asymmetric variable-polarity current, the duration of current flow in straight polarity (balance), and the flow rate of the plasma gas. Increasing the plasma gas flow rate (at constant current amplitude, plasma-nozzle orifice diameter, asymmetric variable-polarity current frequency, and balance) leads to an increase in plasma arc voltage of up to 18%, as well as to a corresponding increase in penetration depth. As the frequency of the asymmetric variable-polarity current increases from 50 to 200 Hz, the penetration depth increases by more than a factor of two. Shifting the polarity balance of the asymmetric variable-polarity current toward reverse polarity (from 85% to 50% straight polarity) results in an increase in the average plasma arc voltage, leading to an increase in weld width and an approximately twofold decrease in penetration depth. The use of pure helium as a shielding gas in plasma arc welding with variable-polarity current of aluminum alloys increases the penetration depth by 45%–90% compared with pure argon. Overall, variations in process parameters during plasma arc welding with asymmetric variable-polarity current exert a significantly stronger influence on weld penetration depth than on weld width.
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Figures(18) / Tables(5)
Volodymyr Korzhyk, Andrii Grynyuk, Yunqiang Zhao, Oleksandr Bushma, Oksana Konoreva, Oleksandr Voitenko, Guirong, Zhe Liu. Influence of plasma arc characteristics on penetration depth and weld formation during welding of Al-Mg-Mn alloy with asymmetric variable polarity current[J]. AIMS Materials Science, 2025, 12(6): 1265-1295. doi: 10.3934/matersci.2025059
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