Figure 1.
The physical and schematic diagram of plasma-GMAW-P hybrid welding system, (a) the physical diagram of plasma-GMAW-P hybrid welding system, and (b) the schematic diagram of plasma-GMAW-P hybrid welding system.
Figure 1.
The physical and schematic diagram of plasma-GMAW-P hybrid welding system, (a) the physical diagram of plasma-GMAW-P hybrid welding system, and (b) the schematic diagram of plasma-GMAW-P hybrid welding system.
Figure 2.
Schematic diagram of plasma−GMAW−P hybrid welding.
Figure 2.
Schematic diagram of plasma−GMAW−P hybrid welding.
Figure 3.
Schematic diagram of plasma−GMAW−P hybrid welding with different types: (a) model 1 (plasma arc was in front and GMAW arc was in rear), (b) model 2 (GMAW arc was in front and plasma arc was in rear), (c) model 3 (plasma arc was located on steel side and GMAW arc was located on Al side), and (d) model 4 (plasma arc was located on Al side, and GMAW arc was located on steel side).
Figure 3.
Schematic diagram of plasma−GMAW−P hybrid welding with different types: (a) model 1 (plasma arc was in front and GMAW arc was in rear), (b) model 2 (GMAW arc was in front and plasma arc was in rear), (c) model 3 (plasma arc was located on steel side and GMAW arc was located on Al side), and (d) model 4 (plasma arc was located on Al side, and GMAW arc was located on steel side).
Figure 4.
The weld formation and the cross-sectional microstructure with different plasma arc currents when the MIG current is 60 A. (a) Plasma arc current is 40 A; (b) plasma arc current is 50 A; (c) plasma arc current is 60 A.
Figure 4.
The weld formation and the cross-sectional microstructure with different plasma arc currents when the MIG current is 60 A. (a) Plasma arc current is 40 A; (b) plasma arc current is 50 A; (c) plasma arc current is 60 A.
Figure 5.
The tensile-shear force of the welded joint with different plasma arc currents when the MIG current is 60 A.
Figure 5.
The tensile-shear force of the welded joint with different plasma arc currents when the MIG current is 60 A.
Figure 6.
The fracture surface of the welded joint with different plasma arc currents when the MIG current is 60 A. (a) Plasma arc current is 40 A; (b) plasma arc current is 50 A; (c) plasma arc current is 60 A.
Figure 6.
The fracture surface of the welded joint with different plasma arc currents when the MIG current is 60 A. (a) Plasma arc current is 40 A; (b) plasma arc current is 50 A; (c) plasma arc current is 60 A.
Figure 7.
The weld formation and optical microstructure of the welded joints with different plasma arc currents when the MIG current is 70 A. (a,e,i) plasma arc current is 30 A; (b,f,j) plasma arc current is 40 A; (c,g,k) plasma arc current is 50 A; (d,h,l) plasma arc current is 60 A.
Figure 7.
The weld formation and optical microstructure of the welded joints with different plasma arc currents when the MIG current is 70 A. (a,e,i) plasma arc current is 30 A; (b,f,j) plasma arc current is 40 A; (c,g,k) plasma arc current is 50 A; (d,h,l) plasma arc current is 60 A.
Figure 8.
The tensile-shear force of the welded joint by plasma-GMAW-P with different plasma arc currents when the MIG current is 70 A.
Figure 8.
The tensile-shear force of the welded joint by plasma-GMAW-P with different plasma arc currents when the MIG current is 70 A.
Figure 9.
The fracture surface of the welded joint by plasma-GMAW-P with different plasma arc currents when the MIG current is 70 A. (a) Plasma arc current is 30 A; (b) plasma arc current is 40 A; (c) plasma arc current is 50 A; (d) plasma arc current is 60 A.
Figure 9.
The fracture surface of the welded joint by plasma-GMAW-P with different plasma arc currents when the MIG current is 70 A. (a) Plasma arc current is 30 A; (b) plasma arc current is 40 A; (c) plasma arc current is 50 A; (d) plasma arc current is 60 A.
Figure 10.
The weld formation of the welded joints with different plasma arc currents when the MIG current is 80 A. (a) Plasma arc current is 10 A; (b) plasma arc current is 20 A; (c) plasma arc current is 30 A; (d) plasma arc current is 40 A.
Figure 10.
The weld formation of the welded joints with different plasma arc currents when the MIG current is 80 A. (a) Plasma arc current is 10 A; (b) plasma arc current is 20 A; (c) plasma arc current is 30 A; (d) plasma arc current is 40 A.
Figure 11.
The tensile-shear force of the welded joint.
Figure 11.
The tensile-shear force of the welded joint.
Figure 12.
The fracture surface of the welded joint. (a) Plasma arc current is 10 A; (b) plasma arc current is 20 A; (c) plasma arc current is 30 A; (d) plasma arc current is 40 A.
Figure 12.
The fracture surface of the welded joint. (a) Plasma arc current is 10 A; (b) plasma arc current is 20 A; (c) plasma arc current is 30 A; (d) plasma arc current is 40 A.
Figure 13.
Optical microstructure of the welded joints. (a,c,e) plasma arc current is 10 A; (b,d,f) plasma arc current is 20 A; (g,i,k) plasma arc current is 30 A; (h,j,l) plasma arc current is 40 A.
Figure 13.
Optical microstructure of the welded joints. (a,c,e) plasma arc current is 10 A; (b,d,f) plasma arc current is 20 A; (g,i,k) plasma arc current is 30 A; (h,j,l) plasma arc current is 40 A.
Figure 14.
The SEM microstructure of the overall image and the enlargement image of zone X with different types of welding wires. (a) ER4043; (b) ER4047; (c) ER1070; (d) ER5356.
Figure 14.
The SEM microstructure of the overall image and the enlargement image of zone X with different types of welding wires. (a) ER4043; (b) ER4047; (c) ER1070; (d) ER5356.
Figure 15.
The tensile-shear force of the welded joints filled with different metals.
Figure 15.
The tensile-shear force of the welded joints filled with different metals.
Figure 16.
The fracture surface of the welded joints filled with different metals. (a) ER4043; (b) ER4047; (c) ER1070; (d) ER5356.
Figure 16.
The fracture surface of the welded joints filled with different metals. (a) ER4043; (b) ER4047; (c) ER1070; (d) ER5356.
Figure 17.
Surface appearances of plasma-GMAW-P with different styles. (a) model 1; (b) model 2; (c) model 3; (d) model 4.
Figure 17.
Surface appearances of plasma-GMAW-P with different styles. (a) model 1; (b) model 2; (c) model 3; (d) model 4.
Figure 18.
Optical microstructure of the joints welded via plasma-GMAW-P with different styles. (a,d,g) model 1; (b,e,h) model 3; (c,f,i) model 4.
Figure 18.
Optical microstructure of the joints welded via plasma-GMAW-P with different styles. (a,d,g) model 1; (b,e,h) model 3; (c,f,i) model 4.
Figure 19.
The SEM microstructure of joints via plasma-GMAW-P with model 1. (a) The overall image; (b) the enlargement image of zone X.
Figure 19.
The SEM microstructure of joints via plasma-GMAW-P with model 1. (a) The overall image; (b) the enlargement image of zone X.
Figure 20.
The SEM microstructure of joints formed via plasma-GMAW-P with model 3. (a) The overall image; (b) the enlargement image of zone X.
Figure 20.
The SEM microstructure of joints formed via plasma-GMAW-P with model 3. (a) The overall image; (b) the enlargement image of zone X.
Figure 21.
The SEM microstructure of joints formed via plasma-GMAW-P with model 4. (a) The overall image; (b) the enlargement image of zone X.
Figure 21.
The SEM microstructure of joints formed via plasma-GMAW-P with model 4. (a) The overall image; (b) the enlargement image of zone X.
Figure 22.
The tensile-shear force of the joint welded by plasma-GMAW-P with different styles.
Figure 22.
The tensile-shear force of the joint welded by plasma-GMAW-P with different styles.
Figure 23.
The fracture surface of the joint welded by plasma-GMAW-P with different styles. (a) model 1; (b) model 3; (c) model 4.
Figure 23.
The fracture surface of the joint welded by plasma-GMAW-P with different styles. (a) model 1; (b) model 3; (c) model 4.
Table 1.
The hybrid process parameters of different styles.
Table 1.
The hybrid process parameters of different styles.
Parameter Set | Plasma Arc Current | MIG Current | Filler Metal |
---|
#1 | 40, 50, 60 | 60 | ER4043 |
#2 | 30, 40, 50, 60 | 70 | ER4043 |
#3 | 10, 20, 30, 40 | 80 | ER4043 |
#4 | 20 | 80 | ER4047, ER1070, ER5356 |
Table 2.
The chemical compositions of different welding wires (wt.%).
Table 2.
The chemical compositions of different welding wires (wt.%).
Welding Wire | Si | Cu | Fe | Mn | Ti | Zn | Mg | Al |
---|
ER4043 | 4.50–6.00 | 0.30 | 0.80 | 0.05 | 0.20 | 0.10 | 0.05 | Bal. |
ER4047 | 11.0–13.0 | 0.30 | 0.80 | 0.15 | - | 0.20 | 0.10 | Bal. |
ER1070 | 0.3 | - | 0.3 | - | - | - | - | Bal. |
ER5356 | 0.25 | 0.10 | 0.40 | 0.05–0.20 | 0.06–0.20 | 0.10 | 4.50–5.50 | Bal. |
Table 3.
The EDS results of joints filled with ER4043.
Table 3.
The EDS results of joints filled with ER4043.
Elements (at.%) | Fe | Al | Si. | Cu | O |
---|
A1 | 98.48 | 0.20 | 0.26 | 1.06 | - |
A2 | 38.90 | 57.91 | 2.37 | 0.82 | - |
A3 | 23.65 | 71.31 | 4.40 | 0.64 | - |
A4 | 3.57 | 88.94 | 6.28 | 0.28 | - |
A5 | 0.32 | 98.10 | - | 0.24 | 0.24 |
Table 4.
The EDS results of joints filled with ER4047.
Table 4.
The EDS results of joints filled with ER4047.
Elements (at.%) | Fe | Al | Si. | Cu | Zn |
---|
A1 | 10.95 | 72.87 | 15.89 | 0.29 | - |
A2 | 9.72 | 66.60 | 23.41 | 0.27 | - |
A3 | 9.89 | 66.60 | 22.95 | 7.33 | - |
A4 | 8.98 | 78.24 | 11.43 | - | 1.35 |
A5 | 13.26 | 63.86 | 21.36 | - | 1.52 |
Table 5.
The EDS results of joints filled with ER1070.
Table 5.
The EDS results of joints filled with ER1070.
Elements (at.%) | Fe | Al | C | Au | O | Mg |
---|
A1 | 76.95 | - | 20.86 | 1.16 | - | - |
A2 | 1.97 | 97.48 | - | - | - | - |
A3 | 78.02 | - | 20.49 | 0.70 | - | - |
A4 | 0.82 | 89.75 | 6.95 | - | 0.75 | 0.98 |
A5 | 77.63 | - | 21.37 | - | - | - |
Table 6.
The EDS results of joints filled with ER5356.
Table 6.
The EDS results of joints filled with ER5356.
Elements (at.%) | Fe | Al | C | Mg | O | Zn |
---|
A1 | 2.13 | 71.04 | 20.64 | 3.84 | 1.24 | - |
A2 | - | 76.37 | 17.41 | 3.85 | 1.71 | - |
A3 | - | 29.93 | 8.29 | 1.20 | 51.95 | 6.23 |
A4 | 0.68 | 64.36 | 16.86 | 1.36 | 6.45 | 10.28 |
A5 | 67.17 | 11.93 | 20.23 | - | - | - |
A6 | 74.49 | - | 24.62 | - | - | - |
A7 | 74.30 | - | 23.41 | - | - | - |
A8 | 0.51 | 33.41 | 18.86 | 2.84 | 37.05 | 6.04 |
A9 | 0.71 | 36.88 | 10.43 | 2.44 | 38.97 | 8.75 |
A10 | 22.31 | 57.95 | 19.74 | - | - | - |