Heat and mass transfer behavior in CMT plus pulse arc manufacturing

The metal transfer mode, temperature distribution, flow behavior, and microstructure characteristic in the process of cold metal transfer plus pulse (CMT+P) arc manufacturing were investigated by the in-situ observation and numerical simulation. A novel coupling model for droplet-pool interaction under the CMT+P arc was established, along with a new heat source model that considered Marangoni forces on droplets. These innovations provided significant insights into the heat and mass transfer mechanisms in the CMT+P hybrid arc manufacturing process. The results show that the droplets generated by the CMT+P hybrid arc exhibited a mixed transfer mode: short-circuit transfer in the CMT period and projected transfer of one droplet per pulse during the pulse period. The short-circuit transfer was more stable than the projected transfer, attributed to the smooth transfer of droplets to the molten pool through the liquid metal bridge, dominated by surface tension and Marangoni forces. The main energy of the molten pool was provided by droplets, which had a dominant ability to melt the substrate. However, the liquid metal bridge in the CMT period slowed down the heat transfer to the molten pool and had significant oscillating and stirring effects. During the pulse period, the droplet was accelerated and projected transfer by gravity and electromagnetic force. After solidification, the microstructure exhibited an alternating distribution of columnar and equiaxed grains from the bottom-up in the monolayer deposited layer, with a deflected fusion interface towards the scanning direction. At the top of the deposited layer, coarse columnar grains were distributed obliquely or laterally, inhibiting the growth of equiaxed grains and forming a distinct boundary with the equiaxed grains below.