Interactive Phenomena in Hybrid KPAW–GMAW-P

A hybrid welding technique formed by combining keyhole plasma arc welding (KPAW) and pulsed gas metal arc welding (GMAW-P) is characterized by the complex interactions of the arc, droplet, keyhole, and weld pool. With the help of a high-speed video camera, zirconia particles, and a thermal camera, the complex interactive phenomena of the hybrid KPAW–GMAW-P process was analyzed. Owing to the formation of a direct-current path between the KPAW cathode (tungsten electrode) and the GMAW anode (welding wire), the ionized plasma arc was extended to the GMA side, causing an expansion of the GMA. The current at the GMAW droplet was diverged; thus, the Lorentz force promoted a more stable one pulse one droplet metal transfer mode compared with that of GMAW-P. The strong backward flow from the keyhole was suppressed because of the pull-push flow pattern on the top surface of the weld pool be-tween the two arcs. As the heat and molten metal in the weld pool were transported from the region near the GMA (high temperature) to the region near the plasma arc (low temperature), the weld pool temperature decreased.