Plasma-MIG hybrid welding, integrating the high energy density and stability of plasma arc with the efficient filler metal deposition of MIG welding, presents a significant potential for joining thick-section aluminum alloys, a critical challenge in industries such as aerospace, marine, and rail transportation. This study systematically investigates the process characteristics and optimizes the key parameters for welding 10mm thick 5083 aluminum alloy. Experiments were conducted using a controlled orthogonal array to evaluate the independent and interactive effects of central parameters including plasma current, MIG current, welding speed, and plasma gas flow rate. The process stability, characterized by arc behavior and droplet transfer, was analyzed through high-speed imaging and electrical signal acquisition. The resultant weld quality was assessed via comprehensive macro- and micro-structural examination, mechanical property testing, and defect analysis. The results demonstrate that a synergistic arc interaction regime, achieved under optimal parameters, yields a stable, constricted welding process with deep penetration and minimal spatter. The optimized welds exhibited full penetration with a favorable weld profile, significantly reduced porosity compared to conventional MIG welds, and a refined microstructure in the fusion zone. Tensile tests revealed joint efficiencies exceeding 90% of the base metal strength, with fractures occurring in the heat-affected zone. The discussion correlates the observed welding phenomena and weld attributes with the underlying thermal and fluid flow conditions governed by the hybrid parameters. This work establishes a practical parameter window and provides fundamental insights into the process mechanics, confirming Plasma-MIG hybrid welding as a robust and efficient method for high-quality joining of thick aluminum plates.

Lihao Peng. Process Characteristics and Parameter Optimization of Plasma-MIG Hybrid Welding for Thick-Plate Aluminum Alloys. Academic Journal of Engineering and Technology Science (2026), Vol. 9, Issue 1: 40-46. https://doi.org/10.25236/AJETS.2026.090105.

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