Plasma ARC Welding

(PAW)
Surendaar D
715519114051
 Content

1. Introduction
2. How plasma welding works
3. Equipment
4. Welding modes in PAW
5. Advantages
6. Disadvantages
7. Applications
1 - Introduction

Arc welding process that produces

coalescence of metals by heating them
with a constricted arc between an electrode
and the work piece (transferred arc) or
between the electrode and the water-
cooled constricting nozzle (non transferred
arc).
Plasma: A gaseous mixture of positive
ions, electrons and neutral gas molecules.
Plasma ARC Welding
2 - How Plasma Welding Works
Plasma
• Gas which is heated to an extremely high temperature and ionized so that
it becomes electrically conductive
• PAW process uses this plasma to transfer an electric arc to the work piece
• The metal to be welded is melted by the intense heat of the arc and fuses
together

Objective of PAW
• To increase the energy level of the arc plasma in a controlled manner
• This is achieved by providing a gas nozzle around a tungsten electrode
operating on direct current electrode negativity
 Variants of PAW
Transferred arc mode

• Arc is struck between the electrode(-) and the work piece(+)

• Used for high speed welding
• Used to weld Ceramics, steels, Aluminum alloys, Copper alloys, Titanium alloys,
Nickel alloys

Non-transferred mode

• Arc is struck between the electrode(-) and the nozzle(+), thus eliminating the
necessity to have the work as a part of the electrical system
• Arc process produces plasma of relatively low energy density
• Since the work piece in non-transferred plasma arc welding is not a part of electric circuit,
the plasma arc torch may move from one work piece to other without extinguishing the
arc
Transferred and Non-Transferred
ARC Welding
 3 - Equipment
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
• Rectifiers are generally preferred over DC generators
• Working with He as an inert gas needs open circuit voltage above
70 volts. This voltage can be obtained by series operation of two
power sources or the arc can be initiated with argon at normal
open circuit voltage and then helium can be switched on...
• High frequency generator and current limiting resistors used for arc
ignition
Shielding Gas
• Shields the molten weld from the atmosphere.
• Two inert gases or gas mixtures are employed.
• Argon(commonly used), Helium, Argon+Hydrogen and Argon+Helium, as
inert gases or gas mixtures.
• Helium is preferred where a broad heat input pattern and flatter cover
pass is desired.
• A mixture of argon and hydrogen supplies heat energy higher than when
only argon is used and thus permits higher arc alloys and stainless
steels.
• For cutting purposes a mixture of argon and hydrogen (10¬ 30%) or that
of nitrogen may be used.
• Hydrogen, because of its dissociation into atomic form and thereafter
recombination generates temperatures above those attained by using
argon or helium alone.
Welding Parameters

• Current 50 to 350 Amps,

• Voltage 27 to 31 Volts,

• Gas flow rates 2 to 40 liters/min. (lower range for orifice gas and
higher range for outer shielding gas),

• Temp of Jet 50000°F (28000°C)

4 - Modes in PAW
Micro-plasma welding
• Welding Current from 0.1A to 15A
• Arc Length is varied up to 20mm
• Used for welding thin mesh sections sheets 0.1thick wire
Medium-plasma welding
• Welding current from 15A to 100A
Keyhole welding
• Welding Current above 100A, where the plasma arc penetrates the
wall thickness.
• Widely used for high-quality joints in aircraft/space, chemical
industries to weld thicker material (up to 10mm of stainless steel) in a
single pass.
5 - Advantages
• Permits faster metal deposition rate and high arc travel speed as compared
to Gas tungsten arc welding
• Uniform penetration with high welding rate is possible
• Stability of arc and Excellent weld quality
• Can produce radiographic quality weld at high speed
• Can weld steel pieces up to about half inch thick, square butt joint
• Useful for semi automatic and automatic processes.
• Process is very fast and clean
• Requires less operator skill due to good tolerance of arc to misalignments
• High penetrating capability (keyhole effect)
6 - Disadvantages
• Special protection is required as Infrared and UV Radiations is produced
• Needs high power electrical equipment
• Gives out ultraviolet and infrared radiation.
• Operation produces a high noise of the order of 100dB
• Expensive equipment;
• Can weld only up to 25mm thickness.
• High distortions and wide welds as a result of high heat
input (in transferred arc process).
• More chances of Electrical hazards.
7 - Applications
• Aerospace Industries
• Foodstuff and Chemical Industries
• Machine and Plant
Construction
• Automobiles and Railways
• Ship Construction
• Tank Equipment and Pipeline
Construction etc.