BISMILLAHIRRAHMANIRRAHIM

&
ASSALAMUALAIKUM
 WELDING
TECHNOLOGY
(LNB21502)

TAKE HOME ASSIGNMENT

(PLASMA ARC WELDING)
P R E PA R E D BY:

M U H A M M A D A M I N N U R S YA H MI B I N
HASMIN
(56215119248)
 INTRODUCTION
• Plasma arc welding (PAW) is an arc welding process similar to gas tungsten arc welding (GTAW).

• The electric arc is formed between an electrode (which is usually but not always made of sintered
tungsten) and the workpiece.
• The key difference from GTAW is that in PAW, by positioning the electrode within the body of the
torch, the plasma arc can be separated from the shielding gas envelope.
• The plasma is then forced through a fine-bore copper nozzle which constricts the arc and the
plasma exits the orifice at high velocities (approaching the speed of sound) and a temperature
approaching 28,000 °C (50,000 °F) or higher.
• Arc plasma is the temporary state of a gas.

• The gas gets ionized after passage of electric current through it and it becomes a conductor of
electricity.
FIGURE OF PROCESS DIAGRAM OF PAW
 PRINCIPLE OF OPERATION OF
PLASMA ARC WELDING
•Plasma arcs are formed using gas in two forms one is laminar flow (low pressure and low
flow) and the second is turbulent flow (high pressure and high flow).
•In the case of plasma welding laminar flow (low pressure and low flow of plasma gas) is
employed to ensure that the molten metal is not blown out of the weld zone.
•The non-transferred arc (pilot arc) is employed during plasma-welding to initiate the welding
process.
•The arc is formed between the electrode (-) and the water-cooled constricting nozzle (+).

•A non-transferred arc is initiated by using a high-frequency unit in the circuit.

•After the initial high-frequency start, the pilot arc (low current) is formed between the elect
by employing a low current.
 PRINCIPLE OF OPERATION OF
PLASMA ARC WELDING
•After the main arc is struck, the nozzle is neutral or in case of welding-mesh using
micro plasma, there can be an option given to have a continuous pilot arc.

•A transferred arc possesses high energy density and plasma jet velocity.

•Microplasma uses current between 0.1 and 10 amps and is used foils, bellow, and
thin sheets

•Medium plasma uses current between 10 and 100 amps and is used for higher-
thickness plate welding with filler wire or autogenous up to 6 mm plates and
metal deposition (hardfacing) using specialised torches and powder feeders (PTA)
using metal powders.

•High-current plasma above 100 amps is used with filler wires welding at high
travel speeds.
 PROCESS PARAMETERS
•Table below depicted the process parameters used for Micro Plasma Arc Welding.

1.2 – 1.7
Stand-off distance (mm)

1.2
Electrode diameter (mm)

0.4 – 0.7
Plasma gas flow rate (lpm)

7-8
Shielding gas flow rate (lpm)

Vertical
Torch Position
 MACHINE SETUP
•Direct-current power source (generator or rectifier) having drooping characteristics
and open circuit voltage of 70 volts or above is suitable for plasma arc welding.

•Rectifiers are generally preferred over DC generators.

•Working with helium as an inert gas needs open circuit voltage above 70 volts.

•This higher voltage can be obtained by series operation of two power sources.

•The arc can be initiated with argon at normal open-circuit voltage and then helium
can be switched on.

•Current 50 to 350 amps, voltage 27 to 31 volts, gas flow rates 2 to 40 liters/minute

(lower range for orifice gas and higher range for outer shielding gas).
FIGURE OF PLASMA ARC
WELDING MACHINE
 BENEFITS OF PLASMA ARC
WELDING
•Torch design allows better control of the arc.

•This method provides more freedom to observe and control the weld.

•The higher the heat concentration and plasma jet allow faster travel speeds.

•The high temperature and high heat concentration of plasma allow the keyhole
effect.

•This provides complete penetration with the single-pass welding of many joints.

•The heat-affected zone is smaller compared to GTAW (Gas Tungsten Arc Welding).

•Plasma Arc Welding use less current input as compared to another welding
process.
 LIMITATION OF PLASMA ARC
WELDING
•Plasma Arc Welding produce wider welds and heat-affected zones compare to LBW
and EBW.
•Plasma welding equipment is very costly. Hence it will have higher startup cost.

•Plasma Arc Welding requires training and specialization to perform plasma welding.

•Plasma Arc Welding produces ultraviolet and infrared radiation.

•This method produces higher noise on the order of about 100db.

•The PAW torch is bulky and hence manual welding is a bit difficult and requires
training as mentioned.