Topic- Effect of Arc Power on Weld Bead Geometry in Micro Plasma Arc Welding of 1 mm AISI 304 Stainless

Steel

Abstract

Micro Plasma Arc Welding (MPAW) is extensively employed for joining thin metallic sheets owing to its stable
arc, concentrated heat source and reduced distortion. Investigations on MPAW evaluate weld quality primarily
through destructive mechanical testing such as tensile strength, hardness and microstructural characterization.
The present work proposes a rapid geometrical assessment methodology for evaluating MPAW weld quality
using weld bead geometry and surface topography measurements.

Autogenous butt welds produced on thin stainless-steel sheets by varying welding current and arc voltage
while maintaining a constant welding speed. Weld cross-sections will be examined using an optical microscope
to determine fusion zone width, heat affected zone width, penetration and reinforcement geometry. The
influence of arc power and heat input on bead geometry and surface quality will be systematically
investigated. Correlations between processing parameters and weld geometry will be established to identify
the conditions producing stable and defect-free welds.

The proposed methodology provides a rapid, non-destructive approach for comparing MPAW weld quality.

The study demonstrates that weld bead geometry can serve as reliable indicators of process stability and weld
quality, offering a practical evaluation tool for process development and industrial quality control.

Keywords: Micro Plasma Arc Welding, Surface Topography, Profilometry, Weld Bead Geometry, Heat Input,
Thin Stainless Steel.

Experiment Current

1 8A

2 8A

3 8A

4 10 A

5 10 A

6 10 A

7 12 A

8 12 A

9 12 A
Topic- Influence of Pulse Frequency on Weld Bead Geometry in Manual Micro Plasma Arc Welding of 1 mm
AISI 304 Stainless Steel

Abstract

Micro Plasma Arc Welding (MPAW) is widely employed for joining thin metallic sheets owing to its high energy
density, stable arc characteristics and superior control over heat input. Numerous studies have investigated the
influence of welding parameters (Current, welding speed, gas flow rate) on the mechanical and metallurgical
properties of MPAW joints, limited attention has been given to the effect of pulse frequency on weld bead
geometry, particularly under manual welding conditions. The present study experimentally investigates the
influence of pulse frequency on the weld bead geometry of 1 mm thick AISI 304 stainless steel welded using a
manual MPAW process.

A series of autogenous butt welds will be produced by varying the pulse frequency while maintaining constant
welding current, shielding gas flow rate, pulse duty cycle and other process parameters. Cross-sectional
specimens prepared using standard metallographic procedures, and weld bead characteristics including bead
width, penetration depth, reinforcement height, fusion zone width and heat-affected zone width will be
measured using an optical microscope. The measured geometrical characteristics are compared to evaluate
the influence of pulse frequency on weld morphology and identify the parameter range that produces stable
and uniform weld beads.

The outcomes of this study are expected to provide practical insights into the role of pulse frequency in
controlling weld bead geometry during manual MPAW of thin stainless-steel sheets.

Keywords: Micro Plasma Arc Welding, Pulse Frequency, Weld Bead Geometry, AISI 304 Stainless Steel, Manual
Welding, Optical Metallography.

 Peak Current = 12 A

 Base Current = 6 A

 Frequency = 20 Hz

 Duty Cycle = 50%

Abstract

Micro Plasma Arc (MPA) technology has emerged as a highly promising process for precision welding of thin
metal sheets and metal additive manufacturing (AM) due to its stable constricted arc, low heat input, and
ability to produce high-quality deposits with minimal distortion. In welding applications, Micro Plasma Arc
Welding (MPAW) offers superior control over the heat source, making it particularly suitable for joining of thin
sheets, precision components, and difficult-to-weld alloys such as stainless steels, titanium alloys, nickel-based
superalloys, and other advanced engineering materials.

This paper presents a comprehensive assessment of the capabilities of Micro Plasma Arc technology in welding
and additive manufacturing. The fundamentals of plasma generation, process characteristics, equipment
configuration, and key process parameters are first discussed. Subsequently, recent developments in MPAW
are reviewed with emphasis on weld quality, microstructural evolution, mechanical properties, process
optimization, and industrial applications. The review further examines the application of Micro Plasma Arc in
additive manufacturing, highlighting deposition mechanisms, material systems, process performance,
advantages, limitations, and comparisons with other metal AM technologies. Finally, current research
challenges, knowledge gaps, and future directions—including intelligent process control, hybrid
manufacturing, real-time monitoring, and multi-material fabrication—are identified.