Shape control of TIG arc plasma by cusp-type magnetic field with permanent magnet

The shape of arc plasma in gas-shielded arc welding is an important factor for the quality and efficiency of the welding. The arc plasma changes its shape by an external magnetic field because the arc is a flow of electricity and is subjected to the electromagnetic force. In this study, we examined the control of arc plasma by a cusp-type magnetic field. The field produces a high and low magnetic area alternatively, and changes the cross-section of the arc plasma from a circular to an elliptical shape. The previous study using solenoid coils to produce a cusp-type magnetic field reported that magnetized arc plasma provided deeper penetration. However, the solenoid device developed for the cusp magnetic field was too large in comparison with the size of the welding torch used for production welding. Therefore, this study investigated the magnetic control of arc plasma with permanent magnets that have recently become smaller in size and higher in intensity. Theoretical analysis model was constructed to determine the optimum arrangement of the magnets. This analysis requires a three-dimensional numerical model because the temperature-, velocity-, and electromagnetic fields of arc plasma change three-dimensionally by the additional magnetic field. It was analytically and experimentally shown in TIG arc welding that the arc shape could be elliptical cross-section even using the permanent magnets. Furthermore, our analysis showed that the effective magnetization direction of magnets was vertical, and this result was confirmed experimentally. As a result, we obtained the good bead appearance in the high-speed welding with this magnetic control.