Free arc heating effect in double-layers hybrid arc source

Keyhole welding process is easily achieved with plasma arc heat source, but the welding speed for a stable keyhole is hard to increase because of the low-level heat input. Higher welding current will increase the heat input, but the induced heavy arc pressure acts to damage the keyhole stability. The narrow window of welding current creates limited usable range of heat input. Double-layers hybrid arc heat source is developed by compositing an outer layer of free arc into the center plasma arc jet. Set the plasma arc current level to create enough arc pressure to open a keyhole, the outer layer arc is used to control additional heat power into the weld pool but has little effect to influence the arc pressure. The free arc heating effect in the hybrid arc is figured out: (1) much faster welding speed can be achieved, it increases from 3 mm/s to 4.75 mm/s after additional 80 A/80 A free arcs are used, and (2) the increase of welding speed is highly related to the total heat input in the hybrid arc and is unrelated to the free arc number; (3) the calculated efficiency factor is selected as 0.75 for the added free arc. The developed hybrid arc is proved to be a robust method to increase the manufacturing efficiency.