An investigation on plasma-MIG hybrid welding process of thick plate aluminum

Plasma-Metal Inert Gas (MIG) hybrid welding was employed to carry out bead on plate welding of an aluminum alloy A5052. The plasma arc was ignited to form a keyhole, and a series of welding systems were developed starting with MIG welding. The convective patterns within the weld pool were meticulously analyzed. In addition, we conducted experimental observations of the flow inside and on the surface of the pool, and we were able to visualize the flow in some areas. The results indicated that the plasma welding side formed a pool that seamlessly integrated the plasma side and the MIG side. At the same time, we observed the formation of a flow pool that integrates both plasma and MIG sides, affecting the formation and behavior of the weld pool. This study aims to provide a nuanced understanding of flow dynamics across the entire pool. This approach is geared towards refining the intricacies of weld pool dynamics for the advancement of welding technologies.