Integrative Evaluation of Bead Morphology in Plasma Transferred Arc Cladding Through Orthogonal Arrays and Morphology Index Analysis

Plasma Transferred Arc (PTA) cladding is a versatile hardfacing technique that produces dense, metallurgically bonded overlays with excellent wear and corrosion resistance. However, optimizing bead shape is challenging due to complex multi-parameter interactions, an issue not fully addressed in existing studies. The bead morphology, defined by height, width, and penetration depth, remains highly sensitive to process parameters, directly affecting dilution and overall coating quality. In this work, single-pass powder PTA cladding was systematically studied using an orthogonal experimental design to assess the effects of arc current, powder feed rate, welding speed, oscillation width, and oscillation speed. A morphology index was proposed to integrate geometric attributes into a single metric for quality evaluation. Regression analysis and finite element simulations based on a Goldak double-ellipsoid heat source revealed that arc current is the dominant factor, where low-to-moderate values (100-115 A) promote wide-shallow pools and higher morphology index values, while higher currents induce excessive penetration and reduced stability. Multi-parameter coupling further indicated that optimal bead morphology is achieved under low-to-moderate current, a high welding speed, relatively high powder feed rate, wide oscillation width, and moderate oscillation speed. A representative optimal condition (100 A, 105 mm·min^-1, 35 g·min^-1, 10 mm, 2600 mm·min^-1) ensured minimal dilution and stable deposition. This integrative framework of orthogonal design, morphology index evaluation, and thermo-fluid simulation provides practical guidelines for parameter optimization and represents a novel combined approach for PTA bead optimization.