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

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Title: Study of Molten Pool Evolution in VP-CMT Aluminium Alloy Arc Additive Manufacturing Under Different EP:EN Ratios.
Authors: Bao, Xulei1 (AUTHOR), Han, Yongquan1,2 (AUTHOR) hanyongquan-imut@outlook.com, Han, Fubiao1,2 (AUTHOR), Liu, Lele1,2 (AUTHOR)
Source: Materials (1996-1944). Mar2026, Vol. 19 Issue 6, p1237. 19p.
Subjects: Electric welding, Negative electrode, Heat flux, Liquid metals, Aluminum alloys
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. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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DbLabel: Engineering Source
An: 192591670
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  Data: Study of Molten Pool Evolution in VP-CMT Aluminium Alloy Arc Additive Manufacturing Under Different EP:EN Ratios.
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  Data: <searchLink fieldCode="AR" term="%22Bao%2C+Xulei%22">Bao, Xulei</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Han%2C+Yongquan%22">Han, Yongquan</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> hanyongquan-imut@outlook.com</i><br /><searchLink fieldCode="AR" term="%22Han%2C+Fubiao%22">Han, Fubiao</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Liu%2C+Lele%22">Liu, Lele</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Mar2026, Vol. 19 Issue 6, p1237. 19p.
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  Data: <searchLink fieldCode="DE" term="%22Electric+welding%22">Electric welding</searchLink><br /><searchLink fieldCode="DE" term="%22Negative+electrode%22">Negative electrode</searchLink><br /><searchLink fieldCode="DE" term="%22Heat+flux%22">Heat flux</searchLink><br /><searchLink fieldCode="DE" term="%22Liquid+metals%22">Liquid metals</searchLink><br /><searchLink fieldCode="DE" term="%22Aluminum+alloys%22">Aluminum alloys</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: 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. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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        Value: 10.3390/ma19061237
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      – Code: eng
        Text: English
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        PageCount: 19
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      – SubjectFull: Electric welding
        Type: general
      – SubjectFull: Negative electrode
        Type: general
      – SubjectFull: Heat flux
        Type: general
      – SubjectFull: Liquid metals
        Type: general
      – SubjectFull: Aluminum alloys
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      – TitleFull: Study of Molten Pool Evolution in VP-CMT Aluminium Alloy Arc Additive Manufacturing Under Different EP:EN Ratios.
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            NameFull: Han, Yongquan
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            NameFull: Han, Fubiao
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            NameFull: Liu, Lele
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            – D: 15
              M: 03
              Text: Mar2026
              Type: published
              Y: 2026
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              Value: 19
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              Value: 6
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            – TitleFull: Materials (1996-1944)
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