Cross-scale process quality control of variable polarity plasma arc welding based on predefined temperature field

Abstract

This study investigates the underlying causes of Variable Polarity Plasma Arc Welding (VPPAW) spatial positional instability and its adverse impact on weld seam quality. Microstructural analysis reveals that the primary cause of poor transverse mechanical properties is the asymmetric distribution of grains. Through the study of heat and mass transfer in the molten pool, it was found that the asymmetric flow of molten metal under the influence of gravity is the main factor leading to uneven temperature distribution and asymmetric grain distribution in the weld pool. A novel approach based on a predefined temperature field is proposed to regulate the weld pool's stability and welding quality. The implementation of the predefined temperature field effectively improves VPPAW weld pool flow, leading to enhanced temperature distribution and grain size and distribution. These findings provide a theoretical foundation and valuable engineering recommendations for achieving high-quality spatial position welding in VPPAW.