In order to reveal the influence of VPPAW on the weld appearance of 5A06 aluminum alloy, the weld appearance is measured and analyzed by single factor control comparison test. Four parameters including positive and negative current, plasma gas flow, positive and negative current duration and wire feed aped are tested and analyzed for their influence on the weld forming. The experiment results show that with the increase of welding current, the reinforcement and width of top weld increases first and then decreases, while the reinforcement of back weld increases dramatically, but the changes of back weld width are not obvious; as the plasma gas flow rate increases, the plasma arc force and the fluidity of weld metal both increase, the reinforcement of back weld increases obviously, while that of top weld decreases; in the case of increasing the duration of the negative current, the reinforcement and width of top weld increase slightly, and the reinforcement and width of back weld decrease; as the wire feed speed increases, the reinforcement of weld increases dramatically and the width of weld increases slightly. The research results may provide some welding process support for VPPA welding of aluminum alloys.