Physical mechanism of material flow and temperature distribution in keyhole plasma arc welding at initial unstable stage

The initial unstable stage associated with keyhole plasma arc welding affects the stability and quality heavily, especially in the non-vertical welding position, which is difficult to control and restricts the process development and application. This work clarifies the temperature distribution and flow behavior of the process from the digging keyhole stage to the keyhole stable movement stage via an infrared thermography system and high-speed camera system. The experimental results showed that the molten metal on the rear side of the keyhole gradually accumulates and solidifies on the exit side and rear wall of the keyhole. When enough molten metal accumulates on the keyhole rear sidewall, it closes under the action of surface tension. The angle (86 degrees -90 degrees) of the keyhole rear sidewall formation can be used to determine whether the keyhole rear side is closed and reached the keyhole stable movement stage. Simultaneously, the influence of the shifting direction of gravity on the temperature distribution, flow behavior, and solidification morphology of the keyhole weld pool was investigated, which further revealed the initial unstable stage of the welding process. In the flat position, at this stage, the high-temperature area within the keyhole rear sidewall surface gradually accumulates close to the exit side of the weld pool. More molten metal flows to the keyhole exit side by gravity and shear forces, which causes a separation area on the keyhole rear side that is nearer to the exit side of the weld pool. This makes it harder to close the keyhole wall when it is in a flat position during the initial unstable stage. Furthermore, the temperature distribution and flow behavior of the keyhole rear side can be used as another factor to characterize the flow state of the weld pool in all positions and stages of welding.