A hybrid arc-wire welding method based on the variable polarity plasma arc (VPPA) and variable polarity pulse metal inert-gas (VP-PMIG) was proposed for manufacturing aluminum alloys. This paper aims to clarify the decoupling control process of heat and mass transfer in the hybrid welding process. To understand the arc physics and analyze the mass transfer behavior, the hybrid arc shape and droplet cross-sectional area with different parameters were obtained by high speed video photography. Further, the melting area of the base metal was analyzed by macro-metallography of the weld bead cross-section to study the heat transfer. It is found that the hybrid arc shape changes with time. The VPPA main arc is deflected to one side by the VP-PMIG, making the temperature distribution asymmetric, and during the VP-PMIG pulse necking occurs. The cross-sectional area of the droplet is more obviously affected by the VP-PMIG current than the VPPA current. Meanwhile, the VPPA current dominates the melting area of the base metal. Therefore, we conclude that heat transfer to the base metal is from the VPPA, while droplet transfer is mainly controlled by the VP-PMIG arc. These conclusions are confirmed by analyzing the decoupling degree of heat and mass transfer of the base metal by the VPPA and VP-PMIG arc.
Keywords: VPPA/PMIG; aluminum alloy; decoupling control; heat and mass transfer.