Melting behavior and forming control of bypass-coupled variable polarity plasma arc additive manufacturing

It can independently control the main current and bypass current as well as the polarity to achieve independent control of the melting of the deposition layer and the melting of the wire, and at the same time, the variable polarity can clean up the oxide film on the surface of the aluminum alloy to achieve high-efficiency arc additive manufacturing of aluminum alloys.

The experimental results show that the droplet transition is different for different wire heights. Complete bridging transfer yields high forming quality in a wide deposition parameters range. Furthermore, changes in the bypass current polarity induce periodic variations in the magnetic field within the coupled arc region, which influences the arc behavior and droplet transfer during the additive manufacturing process.