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WORKING OF PAW

A plasma is a gas which is heated to an extremely high

temperature and ionized so that it becomes electrically
conductive . The plasma arc welding process uses this plasma
to transfer an electric arc to a workpiece .the metal to be
welded is melted by the intense heat of the arc and fuses
together. Here the workpiece has a positive (+)polarity and the
electrode has a negative (-)polarity.
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In the plasma welding torch a tungsten electrode is located

within a copper nozzle having a small opening at the tip. A pilot
arc is initiated between the torch electrode and nozzle tip. This
arc is then transferred to the metal to be welded.

By forcing a plasma gas and arc through a constricted orifice,

the torch delivers a high concentration of heat to a small area.
With high performance welding equipment, the plasma process
produces exceptionally high quality welds.
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TYPES OF PAW

1. Transferred Arc
2 .Non – Transferred Arc

Transferred Arc:

 The arc is formed between the electrode(-) and

workpiece(+).
 Higher penetration is obtained, so thicker sheets can be
weld.
 High amount of energy is transferred to work.
 Higher process efficiency.

 Non – transferred arc :

 The arc is formed between electrode (-)and the constricting

nozzle (+).
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 Less penetration is obtained, so thin sheets can be welded.

 Less energy is transferred to work.

 Lower process eficiency.

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COMPONENTS OF PAW

Power Supply:
 A DC power source (generator
or rectifier) having drooping
characteristics and open
circuit voltage of 70 volts or
above is suitable for PAW.
 This welding can weld at low
ampere of about a 2
ampere.

High frequency generator and current

limiting resistors:
 It is used for arc ignition.

Plasma torch :
 The torch has an electrode and water cooling system
which saves the life of the nozzle and the electrode
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from melting due to excessive heat produced while

welding.

Shielding gases:
 An inert gas, either argon, helium, or a mixture ,is
used for shielding the arc area from the atmosphere.
Argon is more common because it is heavier and
provides better shielding at lower flow rates.

Filler material
 In plasma arc welding there is no filler material is
used. If the filler material is used , then it is directly
fed into the weld zone.
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MODES OF PAW

Micro-plasma welding:

 Welding current from 0.1A to15A.

 Arc length is varied upto 20mm.
 Used for welding thin sheets(0.1mm thick ).

Medium –plasma welding:

 Welding current from 15A to 100A.

 The plasma gas flow rate can be increased to improve
weld pool penetration.

Key hole welding:

 Welding current above 100A.

 It is widely used in high quality joints in space.
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DIFFERENCE B/W PAW AND TIG

Plasma arc welding (PAW):
 Two gases are used one for plasma gas and other for
shielding gas.
 No filler material is required.
 Deep penetration is achieved.
 Inert gas consumption is very high.
 Costly welding equipment.
 Cutting of hard and brittle material is possible

Tungsten inert gas welding (TIG):

 Only one gas is used .which forms plasma as well as
shields the arc and molten weld pool.
 More filler material is required.
 Penetration obtained is not so deeper.
 Inert gas consumption is very low.
 Less welding equipments.
 Cutting of hard and brittle material is not possible.

.
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PROTECTIVE EQUIPMENT REQUIRED DURING PAW

 Helmets
 Gloves Welding
 Safety goggles
 Welding mask
 General fire resistant clothing
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ADVANTAGES

 High welding speed.

 High energy available for welding
 More stable arc produced by PAW method.
 It can work at low amperage.
 High intense arc or high penetration rate.
 PAW has a greater energy concentration.
 Protected electrode allows for more welds before
electrode contamination.
 Extremely short duration welds possible for spot welding
of wires, needles, and micro components.
 Precision the plasma process is generally more precise
than conventional.
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DISADVANTAGES

 Higher equipment cost.

 Noisy operation
 High skill person required.
 High maintenance cost.
 Consumption of inert gas is high.
 Weld only upto 25mm thickness.
 More chances of electrical hazards.
 Proper torch maintenance is critical.
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APPLICATIONS
 Aerospace industries.
 Cryogenics.
 Food stuff and chemical industries.
 Automobiles and railways .
 Ship constriction.
 Tank equipment and pipeline construction etc.