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A thermal-elastoplastici finite element method was built to simulate the process of variable polarity plasma arc welding (VPPAW) for aluminum alloy plates. The welding temperature and stress fields of the aluminum plates with different butt joint parameters(intervals of the joints: D=0.3 mm, 2 mm; and unfitness of the joints: L= 0.3 mm, 2 mm) were calculated using a 3D double-ellipsoidal heat source model. The residual stresses of the welded plates were predicted; the results showed that the unfitness of the joint has a greater impact on the welding residual stresses than that of the interval. The simulated and experimental results were compared and they are consistent well with each other.

A thermal-elastoplastici finite element method was built to simulate the process of variable polarity plasma arc welding (VPPAW) for aluminum alloy plates. The welding temperature and stress fields of the aluminum plates with different butt joint parameters(intervals of the joints: D=0.3 mm, 2 mm; and unfitness of the joints: L= 0.3 mm, 2 mm) were calculated using a 3D double-ellipsoidal heat source model. The residual stresses of the welded plates were predicted; the results showed that the unfitness of the joint has a greater impact on the welding residual stresses than that of the interval. The simulated and experimental results were compared and they are consistent well with each other.