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The low temperature plasma of glow discharge has found a widespread use as a heating source in welding and surface treatment of metals. The meticulous analysis of glow discharge’s instabilities in these processes allowed us to highlight the physicochemical characteristics of the cathode surface (the welded or treated samples) as one of the main reasons of its transition into an electric arc—as a more stable form of gas discharges. The prolonged arc action on the samples surfaces inevitably leads to the disruption of the technological process and, consequently, to undesirable overheating of samples. In this regard, the main aim of this work is to study the influence of the macro- and micro relief of the cathode on the stable glow discharge existence in the processes of metals treatment and diffusion welding. It has been analytically established and experimentally supported that the glow discharge’s stability is mainly affected by the sharp protrusions generated on the cathode surface because of samples pre-treatment by machining before welding. It has been established that the rough surface pre-treatment with the Rz about 60–80 µm decreases the pressure range of glow discharge sustainable existence from 1.33–13.3 kPa to 1.33–5.3 kPa compared with the surface machining with the Rz about 10 µm.

Impact of the Samples’ Surface State on the Glow Discharge Stability in the Metals’ Treatment and Welding Processes