Plasma arc welding: Process, sensing, control and modeling

This article introduces the basic principles of plasma arc welding (PAW) and provides a survey of the latest research and applications in the field. The PAW process is compared to gas tungsten arc welding, its process characteristics are listed, the classification is made, and two modes of operation in PAW, i.e., melt-in and keyhole, are explained. The keyhole mechanism and its influencing factors are introduced. The sensing and control methodologies of the PAW process are reviewed. The coupled behaviors of weld pool and keyhole, the heat transfer and fluid flow as well as three-dimensional modeling and simulation in PAW are discussed. Finally, a novel PAW process variant, the controlled pulse keyholing process and the corresponding experimental system are introduced.