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The ability of arcing wire VPPA to reliable control heat and mass transfer let it have unique advantages in arc additive manufacturing. In this paper, single channel multi-layered aluminum alloy specimens were assembled based on the quadratic general rotary unitized design method, and the mathematical model of single side wall forming dimensions and process parameters was established by multiple regression equations. This model can accurately predict the cladding size of single channel multi-layered aluminum alloy specimen. It was found that the plasma current, travelling speed, and wire feeding speed have significant effect on the layer height, and there is an interaction between the plasma current and travelling speed. For the melting width, the plasma current, variable polarity pulse MIG current and travelling speed have main effect. The width stability control strategy of this process was discussed based on the above results. It is found that the control scheme of the plasma current in the arithmetic progression has obvious advantages in the width stability control.