Arc Pressure Research Articles

Numerical and experimental study of TIG welding arc in high frequency longitudinal magnetic field

The phenomenon of arc compression in TIG welding with high-frequency longitudinal magnetic field (HF-LMF) has been observed. However, its mechanism remains unclear, and there is a lack of numerical investigation. This work presents a two-dimension axisymmetrical model of arc plasma in high-frequency longitudinal magnetic field based on the magnetohydrodynamics (MHD). The distributions of temperature, velocity and pressure of arc plasma in HF-LMF are investigated at different applied LMF frequencies ranging from 0 to 5000 Hz. In order to make the simulation results more convincing, the induced current and the electric force were considered. The results show that the HF-LMF could generate a circumferential electric field, causing particles rotating. However, since HF-LMF is variable, the direction of the electric field also changes, which causes the arc to rotate back and forth. When the frequency of HF-LMF reaches 2000 Hz, the negative pressure zone above the center of the anode disappeared and the arc was compressed. Thus, as the frequency of LMF increases, the distribution of current density, anodic heat flux, and arc pressure changes from a bimodal distribution to a unimodal distribution, and the peak value increases. The theoretical predictions were in good agreement with the experimental results.

Insight into Role of Arc Torch Angle on Wire Arc Additive Manufacturing Characteristics of ZL205A Aluminum Alloy.

The arc torch angle greatly affected the deposition characteristics in the wire arc additive manufacturing (WAAM) process, and the relation between the droplet transition behavior and macrostructure morphology was unclear. This work researched the effect of torch angle on the formation accuracy, droplet transition behavior and the mechanical properties in the WAAM process on a ZL205A aluminum alloy. The results suggested that at the obtuse torch angle, part of the energy input was used to heat the existing molten pool, which was optimized for the longer solidification period of the molten pool. Therefore, the greater layer penetration depth at 100° resulted in the improved layer-by-layer combination ability. The obtuse torch angle was associated with the better formation accuracy on the sidewall surface due to the smaller impact on the molten pool, which was influenced by both the arc pressure and droplet impact force. The eliminated pores were optimized for the mechanical properties of depositions at a torch angle of 100°; thus, the tensile strength and elongation attained maximum values of 258.6 MPa and 17.1%, respectively. These aspects made WAAM an attractive mode for manufacturing large structural components on ZL205A aluminum alloy.

Free arc heating effect in double-layers hybrid arc source

Keyhole welding process is easily achieved with plasma arc heat source, but the welding speed for a stable keyhole is hard to increase because of the low-level heat input. Higher welding current will increase the heat input, but the induced heavy arc pressure acts to damage the keyhole stability. The narrow window of welding current creates limited usable range of heat input. Double-layers hybrid arc heat source is developed by compositing an outer layer of free arc into the center plasma arc jet. Set the plasma arc current level to create enough arc pressure to open a keyhole, the outer layer arc is used to control additional heat power into the weld pool but has little effect to influence the arc pressure. The free arc heating effect in the hybrid arc is figured out: (1) much faster welding speed can be achieved, it increases from 3 mm/s to 4.75 mm/s after additional 80 A/80 A free arcs are used, and (2) the increase of welding speed is highly related to the total heat input in the hybrid arc and is unrelated to the free arc number; (3) the calculated efficiency factor is selected as 0.75 for the added free arc. The developed hybrid arc is proved to be a robust method to increase the manufacturing efficiency.

Modeling of multi-phase flow in plasma transferred arc cladding of NiCrBSi/WC metal matrix composite

In this paper, a 3D multiphase flow model has been established for the plasma transferred arc (PTA) cladding of composite powder (NiCrBSi/50 wt% WC) on a 40CrNi2MoA substrate. The multiphase flow model simulates both the discrete phase (WC particles) and continuous phase in the melt pool, including the behaviors of heat transfer and particle distribution. The buoyancy, arc pressure, surface tension, and electromagnetic force are calculated. The model is then used to predict the influences of welding currents and preheating temperatures on the depth of heat-affected zone (HAZ), the temperature field, and the dimensions of the cladding layers. To validate this model, the dimensions and the HAZ depth are analyzed and compared to experimental data. The results show that the dimensions and HAZ depth obtained by the model simulation are in good agreement with the experiment. The HAZ depth, the melt pool length, and the dimensions of cladding layer would increase with the increasing welding current or preheating temperature. Driven by the inward convection in the melt pool, WC particles tend to distribute around the center line of cladding layers. This is the first work of modeling 3D multiphase flow in PTA cladding process of particle-reinforced metal matrix composite (MMCs). The work can provide theoretical guidance for adjusting process parameters to control HAZ depth and cladding quality in actual production.

Interruption characteristic of 3%C5F10O/97%CO2 gas mixture in a 40.5 kV circuit breaker

The C5F10O/CO2 gas mixture is one of the most promising SF6 alternative gases at the present stage, which was initially applied in high-voltage electrical equipment. This paper mainly studies the interruption performance of 3%C5F10O/97%CO2 gas mixture (k = 3%) with a charging pressure of 0.6 MPa in high-voltage circuit breakers. First, the thermodynamic parameters, transport coefficient, and net radiation coefficient were calculated for k = 3%. On this basis, a 40.5 kV circuit breaker was used as a prototype to establish the magnetohydrody-namic model for breaking 20 kA short-circuit current, and the arc temperature and pressure distribution in the arc extinguishing chamber of the circuit breaker were calculated. The LC oscillation circuit was used to build an arc-extinguishing characteristic test platform to verify the accuracy of the numerical calculation. Finally, based on the Mayr arc model and the critical electric field strength, the post-arc thermal breakdown and electrical breakdown characteristics of SF6, CO2, and k = 3% were quantitatively analyzed. The results show that under 0.6 MPa, the thermal breakdown performance of k = 3% is about 89.7% of SF6, which is nearly twice higher than that of CO2 and has better thermal breaking ability. The electrical breakdown performance of k = 3% is about 20.4% of SF6, and the probability of electrical breakdown in the front end of the fixed contact is high. This problem should be paid attention to in the design of high-voltage circuit breakers. This study can provide a reference for the development and optimization of environmentally friendly high-voltage circuit breakers.

Numerical evaluation of interwire angle influence on molten pool fluid dynamics and weld defects in tandem NG-GMAW of 5083 aluminum alloy

The impact of interwire angle on the fluid dynamics and weld defects in tandem NG-GMAW of 5083 AlMg alloy was investigated through experimental and simulation methods. The rotating coordinate system was employed to model the inclined arc and arc interaction, while a pulsed Gaussian distribution arc model was adopted to consider factors such as arc heat, arc pressure and drag force. Experimental results demonstrate that different interwire angles lead to different weld formation and varying levels of porosity and pore distribution. A sound weld bead with no formation defect and low porosity was achieved when the interwire angle was set at 10°. Simulation results illustrate the relationship between weld formation, bubble escape and molten pool fluid dynamics under diverse interwire angles. As the interwire angle increases, the weld surface becomes concave. At the interwire angle of 0°, the weld bead surface appears leveled and porosity tends to occur near the sidewalls due to roundabout flows in that region. At an interwire angle of 14°, roundabout flows converge at the central longitudinal section, resulting in significant porosity in this area. However, when the interwire angle is set at 10°, backward flows driven by two arcs suppresses roundabout flow throughout the entire molten pool, leading to a lower percentage of porosity area.

Analysis of the pressure drop of sulfur hexafluoride (sf6) gas in a circuit breaker 150 KV Siemens 3AQ1EG

Abstract. The development of technology in the current era is very rapid and has an impact on increasing electrical energy which is a major need for large industries and households. One of the electrical energy delivery equipment in the transmission system is a PMT or High Connection Breaker. This PMT is a mechanical equipment equipped with sulfur hexafluoride (SF6) gas arc extinguishing media. The process of extinguishing the arc occurs due to contact due to work from the movement that causes the contact to cause an arc. This decrease in SF6 gas pressure greatly affects reliability when operating, because the arc extinguishing process is not perfect. This is determined by the age of the equipment and the number of operating breakers. The results showed that SF6 gas which is in accordance with the standard normal pressure of 6.4 bar with an ambient temperature of 34°C can minimize the occurrence of equipment damage because it is able to approach arc pressure with SF6 gas velocity of 58 cm/s.kA, with a contact gap of 3,61224. cm, while the PMT cannot be operated at a pressure of 5.2 bar with an ambient temperature of 34°C because the speed of SF6 gas is 82 cm/s.kA with a contact gap of 5.10696. It is concluded that the higher the pressure affects the speed and distance when extinguishing the arc. several factors that affect the decrease in SF6 gas pressure using the FMEA method based on the highest value of the Risk Priority Number (RPN) of 810. Keywords: fire arc, Breakdown, Voltage breaker, SF6 . gas pressure

Stable DC vacuum arc plasma generation from a 100 mm TiB2 cathode

Titanium diboride exhibits outstanding properties for hard and wear resistant coatings. However, efficient physical vapor deposition (PVD) processing through DC vacuum arc, with a deposition rate unreachable for any other PVD technique, is comparatively unexplored for TiB2 thin films due to challenges associated with the film synthesis process. In this work, we used an industrial scale arc plasma source having a plane cathode of 100 mm in diameter and a permanent magnet on its back side. We present analysis of the cathode surface, plasma generation/composition, as well as analysis of collected macroparticles. The cathode weight loss and the amount of generated macroparticles were measured as a function of process parameters (arc current and pressure, in both Ar and N2 gas). Plasma analysis shows average ion energies around 120 and 25 eV for Ti and B, respectively, and plasma ion composition of approximately 50 % Ti and 50 % B. The cathode weight loss was around 0.3–0.5 g/min, of which at least 25 % is estimated to be macroparticles. Notably, the intensity of the macroparticle generation was reduced with an increase in N2 pressure. Altogether, the results show a stable and reproducible plasma generation process and a high potential for the use of the cathodic arc as an efficient and useful method for deposition of metal borides.

Explainable artificial intelligence modeling of internal arc in a medium voltage switchgear based on different CFD simulations

The internal arc represents an unintentional release of electrical energy within the switchgear industry. Manufacturers must address this electro-thermal issue in their switchgears. Over the past decades, various researchers and engineering groups have examined the internal arc pressure rise in switchgears to mitigate damages. The high variability in pressure rise among switchgears due to diverse factors such as design, manufacturing, and electrical parameters results in varying reported pressure increases. This issue motivates the application of artificial intelligence (AI) in interpreting internal arc modeling. The present paper explores the impact of manufacturing parameters such as total duct width (TDW), height (H), and ducts condition (DC), along with environmental parameters like initial pressure (IP) and initial temperature (IT), on the maximum pressure (MP) generated during an internal arc in a medium voltage (MV) switchgear. For this purpose, 54 different computational fluid dynamics (CFD) models were built using the parameters indicated. An extreme gradient boosting (XGBoost) machine learning (ML) model was trained using different CFD models, with MP serving as the target variable for the ML model. The obtained results reveal a variation in the MP of the internal arc under the mentioned parameters, ranging from 17835.45 Pa to 144423.2 Pa. Using SHAP data revealed that IP, TDW, and DC were the most significant factors affecting the pressure increase of the internal arc phenomena.

Experimental research on the influence of HTS tape width and former type on the transverse compression performance of CORC cables

The huge transverse Lorentz force experienced by CORC cable during the operation of fusion projects may cause irreversible degradation of its current-carrying capacity. Therefore, it is particularly important to study the influence of cable parameters on their transverse compression performance, and use these influence laws to adjust cable parameters to improve the critical value of transverse compression load that CORC cables can withstand. Solid copper bar former CORC cables with a former diameter of 5.57 mm are produced using HTS (high temperature superconducting) tapes (manufactured by Shanghai Superconductor) of 4 mm and 5 mm width respectively. The experimental results show that the CORC cable wound with 5 mm wide HTS tape has a greater critical transverse compression load than the cable wound with 4 mm wide HTS tape. This indicates that using wider HTS tapes to wind CORC cables can effectively improve their transverse compression performance. A solid copper bar former CORC cable and a stainless steel spiral tube former CORC cable are also produced. Through transverse compression experiments, it is found that the critical transverse compression load of the solid copper bar former and the stainless steel spiral tube former CORC cable are 130 kN/m and 89 kN/m, respectively. This indicates that the solid copper bar former CORC cable has better transverse compression performance. In addition, we also compared the influences of flat and arc pressure blocks on the transverse compression performance of CORC cables, and this experimental results provided a basis for the selection of the bobbin structure when using CORC cables to make coils.

Interaction Mechanism of Arc, Keyhole, and Weld Pool in Keyhole Plasma Arc Welding: A Review.

The Keyhole Plasma Arc Welding (KPAW) process utilizes arc plasma highly constricted by a water-cooled cupper nozzle to produce great arc pressure for opening a keyhole in the weld pool, achieving full penetration to the thick plate. However, advanced control of welding is known to still be difficult due to the complexity of the process mechanism, in which thermal and dynamic interactions among the arc, keyhole, and weld pool are critically important. In KPAW, two large eddies are generally formed in the weld pool behind the keyhole by plasma shear force as the dominant driving force. These govern the heat transport process in the weld pool and have a strong influence on the weld pool formation process. The weld pool flow velocity is much faster than those of other welding processes such as Tungsten Inert Gas (TIG) welding and Gas Metal Arc (GMA) welding, enhancing the heat transport to lower the weld pool surface temperature. Since the strength and direction of this shear force strongly depend on the keyhole shape, it is possible to control the weld pool formation process by changing the keyhole shape by adjusting the torch design and operating parameters. If the lower eddy is relatively stronger, the heat transport to the bottom side increases and the penetration increases. However, burn-through is more likely to occur, and heat transport to the top side decreases, causing undercut. In order to realize further sophistication of KPAW, a deep theoretical understanding of the process mechanism is essential. In this article, the recent progress in studies regarding the interaction mechanism of arc, keyhole, and weld pool in KPAW is reviewed.

A novel optimizing Pulsed Plasma Gas Variable Polarity Plasma Arc Welding (PPG-VPPAW) method for improving weld quality

To enhance the reliability of aluminum alloy welding quality, a novel Pulsed Plasma Gas Variable Polarity Plasma Arc Welding (PPG-VPPAW) system is proposed. This system enables independent control and rapid adjustment of the plasma gas, allowing for flexible modulation of arc pressure output under constant thermal conditions, thereby reducing porosity and refining grain structure. The research analyzed the impact of parameters of different plasma gas on arc characteristics, welding porosity, and welding microstructure. The results reveal that the periodic changes in pulsed plasma gas induce corresponding variations in arc temperature, arc shape, arc pressure, arc voltage, and the morphology of the weld pool keyhole. The magnitude of the difference between the base value and peak value of pulsed plasma gas determines the extent of arc pressure fluctuations and the behavior of the backside keyhole. The maximum oscillation amplitude of the backside keyhole can reach up to 4.5 mm². Additionally, the oscillation of pulsed plasma gas within the molten pool has been demonstrated to effectively reduce weld porosity and refine grain size. Under this process, the grain size of the weld metal can be reduced by up to approximately 25%. Current work provides an important direction for fabricating highly reliable aluminum alloy weldments.

A novel magnetic field assisted powder arc additive manufacturing for Ti60 titanium alloy: Method, microstructure and mechanical properties

Due to the rapid heating-cooling process and unstable keyhole, pore defects are easily formed during the high energy beam-powder additive manufacturing (AM) process, posing great challenges to the high-performance manufacturing of aerospace components. Using an arc with lower energy density as a heat source can effectively avoid these defects, but its matching raw materials are limited to wire. In this paper, a novel magnetic field assisted powder arc additive manufacturing (MFA-PAAM) method has been proposed, which combines arc heat source and powder raw material to achieve dense metal parts. A transverse magnetic field (TMF) was introduced to solve the powder spattering problem which impacts the stability of the PAAM process, by regulating the direction of the arc plasma flow and the arc pressure. The unique melting behavior of the powder under arc heating was captured by a high-speed camera, which can be summarized into two steps: balling and adsorption by the molten pool. And the well-formed and fully dense Ti60 high-temperature titanium alloy wall components were successfully manufactured using the self-developed equipment. The microstructure of the thin-wall component is dominated by basket-weave distributed α laths and few β sheets remaining at their boundaries. A layered periodic distribution along the building direction was observed, which is mainly distinguished from the content and morphology of the β phase. The average ultimate tensile strength (UTS) and elongation to failure in the travelling direction are 1003.2 MPa and 15.1%, while the average UTS and elongation along the building direction are 1009.3 MPa and 16.6%, respectively. The fracture morphologies in both directions are characterized by ductile fracture. The MFA-PAAM technique shows great potential for fabricating materials that are difficult to be drawn into wires with high efficiency and performance.

Influence of reduced pressure on arc and weld pool properties in TIG welding

In this article, transient transport phenomena in the arc and weld pool for different ambient pressures during tungsten inert gas welding were reported. Arc plasma and weld pool behaviour vary with ambient pressure because of changes in arc thermophysical properties. The maximum arc temperature decreases with decreasing ambient pressure because of reduced plasma electrical conductivity. Decreased arc mass density results in a lower maximum weld pool surface temperature and a decrease in maximum metal vapour content as ambient pressure decreases. Arc pressure decreases with decrease in ambient pressure, resulting in shallower penetration. Calculated arc temperature distribution and weld cross-section are compared with experiments to validate the modeling method for simulating heat and mass transfer phenomena in low ambient pressure welding.

Experimental study on compressive strength of in situ concrete tested with arc pressure method

The innovative arc pressure testing method (APTM) is adopted in this study to obtain the strength of in situ concrete and reduce damage to the concrete structure. This method is related to the double shear plane of the concrete core. A specific APTM apparatus is used to apply loads in order to obtain the approximate pure shear stress and shear strength of the concrete core. Factors affecting the strength of concrete, such as aggregate type and concrete moisture, were found not to have an impact of the applicability of APTM. The compressive strength range of the tested cube concrete samples is 20–60 MPa. The reliability and repeatability of APTM are superior to in situ testing techniques such as Schmidt hammer (SRH) and pull-off testing methods. The experimental results indicate that APTM is suitable for in situ testing of concrete compressive strength of prefabricated buildings and beam–column joints in dense steel structures. Compared with other testing methods, its accuracy is much higher and the damage to the structure is minimised.

Measurement and analysis of arc pressure in two-TIG welding

The distributions of the arc pressure at the anode surface along the directions of the tungsten electrode alignment (x-axis) and that perpendicular to the x-axis (y-axis) in two-TIG welding were measured and analyzed with the aid of the numerical results. The influences of the electrode spacing, the proportion of the current through the electrodes with the same total current, the total current and the arc length on the arc pressure were investigated. The results showed that the two-TIG arc pressure is significantly lower than the single-TIG arc under the same conditions, and the distribution range is noticeably reduced. As the tungsten electrode spacing increases, the arc pressure decreases, and the direction in which the arc pressure distribution extends changes from the x-axis to the y-axis. When the currents through the two tungsten electrodes are different, the arc pressure distribution in the x-axis is not symmetrical but symmetrical in the y-axis. As the current ratio or the total current increases, the maximum arc pressure increases and the deviation of the maximum arc pressure from the central point becomes more pronounced. The arc pressure decreases as the arc length increases, and its distribution range extends more along the y-axis.

Keyhole Welding with Hybrid Plasma-Free Arc Source

Improving the keyhole welding process window is challenging work because the force and thermal state in the weld pool are hard to control. A hybrid plasma-free arc source was developed based on a plasma arc torch, sided tungsten was added close to the constraint orifice to form a free arc, and hybrid arcs formed after the free arc was fully absorbed into the constraint arc. In such a one-anode, twocathode hybrid arc system, the added free arc acts in an assistant role to adjust arc heat output without influencing the arc pressure peak, and the constraint arc acts as the guiding arc to control the arc pressure and slightly incline to the free arc side. Bead-on welding experiments were done to test keyhole welding process behavior with the hybrid arc source, including arc column, keyhole state, weld surface performance, and melting state in the weld pool. Results showed that (1) the hybrid arc can enlarge the stable keyhole welding process window in aspects of welding current and welding speed, and a more-obvious improving effect is obtained with the leading-sided tungsten; (2) the hybrid arc with the rear-sided tungsten has a smooth front weld surface; (3) the increased heat will enlarge the weld cross-section area with no obvious influence to the backside weld width; and (4) the leading keyhole wall is related to the outer tungsten position. The research gives a new method for improving keyhole welding stability.

Keyhole Welding with Hybrid Plasma-Free Arc Source

Improving the keyhole welding process window is challenging work because the force and thermal state in the weld pool are hard to control. A hybrid plasma-free arc source was developed based on a plasma arc torch, sided tungsten was added close to the constraint orifice to form a free arc, and hybrid arcs formed after the free arc was fully absorbed into the constraint arc. In such a one-anode, twocathode hybrid arc system, the added free arc acts in an assistant role to adjust arc heat output without influencing the arc pressure peak, and the constraint arc acts as the guiding arc to control the arc pressure and slightly incline to the free arc side. Bead-on welding experiments were done to test keyhole welding process behavior with the hybrid arc source, including arc column, keyhole state, weld surface performance, and melting state in the weld pool. Results showed that (1) the hybrid arc can enlarge the stable keyhole welding process window in aspects of welding current and welding speed, and a more-obvious improving effect is obtained with the leading-sided tungsten; (2) the hybrid arc with the rear-sided tungsten has a smooth front weld surface; (3) the increased heat will enlarge the weld cross-section area with no obvious influence to the backside weld width; and (4) the leading keyhole wall is related to the outer tungsten position. The research gives a new method for improving keyhole welding stability.

Experimental and Numerical Investigation of the Thermal and Force Regulation Mechanism of Bypass Coupling Double-Sided Arc Welding Based on 6061 Aluminum Alloy

In this study, 6061 aluminum alloy was proposed for welding using bypass coupling double-sided arc welding (BCO-DASW) to further improve its welding quality and efficiency. To gain insight into the thermal and force regulation mechanism of the BCO-DASW of 6061 aluminum alloy, the dynamic effects of the high-temperature plasma inside the arc with various parameters were fully compared and investigated through the combined method of the physical experiment and the numerical simulation. The thermal flow field of the hybrid arc was analyzed numerically. Furthermore, its working adaptability and mechanical behaviors were studied experimentally. The results show that a single penetration of the 6 mm sheets can be achieved without visible defects when the center offset of the arcs is within 3 mm on both sides of the base metal during BCO-DASW. Through the thermal analysis, it was found that, compared with the MIG process, the introduction of the bypass arc lead to a temperature decrease at the bottom of the hybrid arc due to energy redistribution. Furthermore, through the kinetic analysis, it was found that not only could the level of arc pressure be reduced, but also the action range of the arc pressure could be regulated up to 4.6 mm. The thermal force regulation mechanism worked together to enhance the stability of the molten pool and achieves good joint strength during the BCO-DASW of 6061 aluminum alloy. This research not only has great significance in further improving the welding quality and efficiency of aluminum alloy, but also deeper understanding of the energy regulation mechanism during aluminum alloy welding.

Study on coupling characteristics of different welding modes in laser-double TIG hybrid welding

In order to study the low-power pulsed laser-induced double arc coupling discharge effect and improve the energy utilization rate of the hybrid heat source, this paper adopts different heat source arrangement modes (laser-guided, double arc-guided) and conducts welding experiments under different Dla (distance between laser beam and two tungsten electrodes). The high-speed camera and spectral diagnostic system are used to monitor the dynamic behavior of arc plasma information, molten pool, and keyhole in real-time and calculate the characteristics of electron temperature and electron density of the coupled plasma. The physical model is established to analyze and discuss the time characteristics and energy distribution of coupled discharge. The results show that according to the different Dla, the hybrid heat source has three different coupling effects: laser and double arc interfere with each other, laser and double arc good coupling, laser and double arc no significant effect. When the laser and the double arc have a good coupling state, the coupled plasma has a lower electron temperature and a higher electron density. At this time, the Marangoni force and arc pressure on the liquid metal in the laser keyhole is enough to overcome its own gravity. The keyhole has existed for a long time, which is conducive to the extension of the laser-arc coupling discharge effect and improves the energy utilization efficiency of the hybrid heat source. Compared with the laser-guided mode, the double arc-guided mode has a larger coupling discharge period and duty cycle, and the energy density of the conductive region in the center of the keyhole increases by 14.4 %, which is beneficial to improve the energy utilization efficiency of the hybrid heat source and obtain a larger penetration depth.