Study of Molten Pool Evolution in VP-CMT Aluminium Alloy Arc Additive Manufacturing Under Different EP:EN Ratios.

Abstract

This study investigates the influence of varying positive-negative polarity ratios (EP:EN) on melt pool evolution during alternating current CMT (VP-CMT) arc additive manufacturing through a combined experimental and numerical approach. A multi-layer single-track droplet-melt pool coupling model was established, revealing the regulatory mechanisms governing melt pool flow, temperature distribution, and dimensional changes. These are driven by differences in arc morphology, heat input, and mechanical forces during EP and EN phases. Results indicate that molten pool flow is primarily governed by wire feed, retraction, and Marangoni forces. During the EP phase, arc divergence and elevated heat input result in significantly higher flow velocities than in the EN phase. Molten pool length increases with rising EP proportion, exhibiting periodic dynamic variations. Lateral flow intensity intensifies as EP ratio increases, directly influencing cladding layer morphology. This study provides theoretical basis for optimising additive manufacturing quality by adjusting the EP:EN ratio.