In-situ X-ray imaging of the breakup dynamics of current-carrying molten metal jets during arc discharge

The flow dynamics of current-carrying molten metal jet breakup during arc discharge serves as mass and heat sources in wire-arc-based metal deposition processes, thereby optimizing the resultant product quality. However, the spatiotemporal flow interaction between the molten metal jet and the surrounding arc plasma remains unclear. Here, using in-situ synchrotron X-ray imaging, we simultaneously track surface deformation and internal flow in molten aluminum jets during argon arc discharge. We reveal that modulating the magnitude and path of the arc discharge current can accelerate the jet velocity by 200–300% beyond its initial injection speed, thereby facilitating significant jet elongation. Our results provide consistent evidence that the jet flow dynamics are predominantly governed by the interaction between the arc discharge current and its coaxial self-induced magnetic field. This study establishes a framework at the intersection of fluid dynamics and electromagnetism, contributing to optimized control and precision in wire-arc-based applications. Understanding the dynamics of the breakup of current-carrying molten metal jets during arc discharge is vital in metal deposition processes. Here, X-ray imaging of a molten aluminum jet reveals how process parameters can be used to control jet dynamics, such as velocity.