Abstract
When welding with 5xxx series aluminium filler wires, explosion of droplets occurs during droplet transfer, which results in spatter formation. In plasma-GMA (gas metal arc) hybrid welding, the coaxial plasma arc surrounding the GMA enables more stable droplet transfer and lower GMA current. In this study, bead-on-plate welding tests were conducted using conventional GMA welding and plasma-GMA hybrid welding. Droplet transfer behaviours for both processes were observed using high-speed imaging, and droplet explosion behaviour was analysed under various welding conditions. In plasma-GMA welding, the droplet transfer was stabilized without in-flight explosion, even for high welding current and higher melting rate was achieved by the additional plasma arc.
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