Characterization of the Arc Pattern and Melt Pool of 5454 Aluminum Alloy

WANG Gang; LI Yanqing; REN Zeliang; XIU Yanfei; LIU Wei; WANG Hougao; YU Jie; CHENG Lin; DOU Cunyin

doi:10.3969/j.issn.1674-6457.2025.08.024

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (8) : 229-237. DOI: 10.3969/j.issn.1674-6457.2025.08.024

Advanced Manufacturing Technology and Equipment

Characterization of the Arc Pattern and Melt Pool of 5454 Aluminum Alloy

WANG Gang^1,2, LI Yanqing^1,2,*, REN Zeliang^1,2, XIU Yanfei^1,2, LIU Wei^1,2, WANG Hougao^1,2, YU Jie^1,2, CHENG Lin¹, DOU Cunyin^1,2

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Abstract

The work aims to investigate the melt pool behavior (including the geometric characteristics of the melt pool and the liquid metal flow direction) and arc morphology of 5454 aluminum alloy under different welding conditions. Pulsed metal inert gas (MIG) and cold metal transfer (CMT) were used for welding and the melt pool behavior and arc morphology of 5454 aluminum alloy during the overlay welding process under different welding conditions were observed and analyzed. In addition, through the analysis on the temperature field during the welding process, the effect characteristics of different shielding gases on the arc were also considered. As the proportion of helium in the welding shielding gas rose, the average diameter of the arc gradually decreased, the stability was improved, and the ionization energy of the arc was enhanced, which contributed to the gradual increase of the temperature of the arc in the process of continuous and stable combustion, and the highest temperature point affected by the arc increased from 1 959.1 ℃ in pure argon to 2 210 ℃ in pure helium. Compared with pulsed MIG, the CMT method had a shorter arc length, a smaller melt pool size, a more concentrated temperature, and a greater density and height of liquid metal ripples, but the arc stability during arc initiation was poorer. The behavior and temperature characteristics of the arc are significantly affected by varying shielding gas compositions. Compared to pulsed MIG welding, the CMT method contributes to a shorter arc length, a smaller melt pool size, and a higher temperature concentration. Although less stable during arc initiation, the CMT method forms a weld surface with a higher quality of fish scale pattern. This difference mainly stems from the difference between the two welding methods in arc control and droplet transition. The thorough removal of the oxide film on the surface of the melt pool has a significant effect on the improvement of arc stability and the reduction of the impact on the melt pool. When there is less oxide film on the surface of the melt pool, the arc stability is higher, and the frequency and height of the liquid metal ripple spreading to the edge of the melt pool change less. In the welding operation, the temperature field generated by the heat source shows an elliptical distribution, and its isotherms present an elliptical extension characteristic in the heat affected zone. With the increase of helium content in the shielding gas, the ionization voltage of the gas increases, which in turn enhances the arc power, helps to improve the welding efficiency and the temperature of the arc, effectively reduces the thermal stress during the welding process, and promotes the contraction of the arc column, reduces the cooling rate of the melt pool, and inhibits the generation of hydrogen gas holes in the joint.

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aluminum alloy / pulsed MIG / arc morphology / melt pool characteristics / shielding gas

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WANG Gang, LI Yanqing, REN Zeliang, XIU Yanfei, LIU Wei, WANG Hougao, YU Jie, CHENG Lin, DOU Cunyin. Characterization of the Arc Pattern and Melt Pool of 5454 Aluminum Alloy[J]. Journal of Netshape Forming Engineering. 2025, 17(8): 229-237 https://doi.org/10.3969/j.issn.1674-6457.2025.08.024

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