Research on arc cladding forming process under different inclination angles

Abstract This paper investigates the effect of different substrate inclination angles on the arc cladding process using arc cladding technology. The study uses a combination of experiments and simulations, assisted by high-speed camera verification, to investigate the effects of changes in process parameters on the formation of weld surfaces. Simulation results show that under the same process parameter conditions, the heat input of the molten pool is consistent for different inclination angles, and the highest temperature throughout the process is 1517°C. The equivalent stress is concentrated at the centre of the weld seam, and as the inclination angle increases, the stress first increases and then decreases. As the substrate inclination angle increases, the melt height, melt width, and melt depth exhibit an initial increase followed by a subsequent decrease. The maximum values are achieved at 45°, including a melt height of 2.25 mm, a melt width of 6 mm, and a melt depth of 0.99 mm. The welding voltage was increased from 18V to 26V. The melt width increased with the increase in voltage, while the melt height and depth first increased and then decreased, reaching their peak at 20V. As the current increases, the melt width fluctuates within a certain range, while the melt height and melt depth continue to increase. This study provides a theoretical basis and practical guidance for the arc cladding process on inclined substrates and for improving the morphology of asymmetric welds.