Plasma Arc Machining

Prof. Sachin N. Sawant

Introduction
• The plasma arc machining process was
introduced to the industries in 1964 as a
method of bringing better control to the arc
welding process in lower current ranges.

• Plasma-arc machining (PAM) employs a high-

velocity jet of high temperature gas to melt
and displace material in its path.

• Today, plasma retains the original advantages

it brought to industry by providing an
advanced level of control and accuracy.
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Introduction
• Plasma are initially employed to cut metals that

are difficult to machine by conventional methods.

• Plasma arc has been successfully used for

spraying, surfacing & welding metals like

aluminum, stainless steel, titanium , brass and

copper though other conductive metals may be

cut as well.

• Plasma cutting is a process that cuts through

electrically conductive materials by means of an

accelerated jet of hot plasma.

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 • Plasma cutting is often used in
fabrication and welding shops,
automotive repair and restoration,
industrial construction, salvage and
scrapping operations.

• Due to the high speed, precision cuts,

combined with low cost of operation,
plasma cutting sees a widespread usage
from large scale industrial CNC
applications down to small shops.
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Technology Development

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What is Plasma
• Gases when heated to elevated
temperature, they turn into a distinctly
different type of matter which is called as
plasma

• This change takes place when gases are

heated to very high temperature

• The number of collisions between the

atoms, either elastic or inelastic increases.

• The gas ionizes ,so that a portion of atoms

are stripped off from outer electrons
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What is Plasma
• The electrons thus produced, in turn colloids with
atoms, so that there thermal kinetic energy
increases, and a light is emitted from them ,thus
producing more number of atoms and electrons

• Gases are heated and charged to plasma state.

• Plasma state is the superheated and electrically

ionized gases at approximately 5000⁰C.

• These gases are directed on the workpiece in the

form of high velocity stream.

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Characteristics of Plasma
• Glowing ionized gas results from heating of material to extremely high temp

• Composed of free electrons dissociated from the main gas atoms

• A gas in plasma state becomes electrically conductive as well as responsive to

magnetism fourth state of matter

• Plasma is encountered in electrical discharges

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Generation of Plasma
• First of all the gases are heated to very high temperature
of about 16000 degree Celsius so as to generate plasma.

• This can be achieved by applying a suitable electric field

across the gas column.

• The gases are then heated by an applied electric field.

• An igniter supplies the initial electrons ,which accelerated

before colliding & ionizing.

• The free electrons get accelerated & causes ionization &

heating of gases.

• This process continues till the steady state is obtained.

• The actual heating takes place when atoms recombines

into molecules.

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Principle
• A gas molecule at room temperature consists of two or more atoms. When such a gas is
heated to a high temperature of the order of 2000°C or so, the molecules separate out as
atoms.

• If the temperature is raised to 3000 oC, the electrons from some of the atoms dissociate and
the gas becomes ionized consisting of ions and electrons.

• This state of gas is known as plasma. Thus, plasma is the glowing, ionized gas that results
from heating of a material to extremely high temperature.

• It is composed of free electrons dissociated from the main gas atoms.

• A gas in plasma state becomes electrically conductive as well as responsive to magnetism.

Because of such behavior, plasma is also known as a fourth state o f matter.

• The source of heat generation in plasma is the recombination of electrons and ions into atom
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Principle
• The plasma is encountered in electrical discharges.

• The source of heat generation in plasma is the recombination of electrons and ions into
atoms, or recombination of atoms into molecules.

• This liberated bonding energy is responsible for increased kinetic energy of the atoms or
molecules formed by recombination.

• The temperature of plasma can be of the order of 33,000°C. When such a high temperature
source reacts with work material, the work material melts out and may even vaporize, and
finally is cut into pieces.

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Principle
• In this case, the high velocity electrons of
are collide with the gas molecules & metal
to form ionization of beam.

• The plasma gas is forced through nozzle

duct & is made to direct on the work piece
to be machined.

• Much of the heating takes place in duct at

about 1600 degree Celsius & metal
removal is due to electron bombardment &
hot plasma
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Mechanism of Material Removal
• The metal removal in PAM is due to high
temperature of gases.

• The heating of work piece is due to direct electron

bombardment plus convective heating of hot
plasma.

• The heat produced is sufficient to raise the

temperature above its melting point.

• Approximately 45% of electrical power delivered to

torch is used for removal metal from work piece.

• PAM is used for cutting, spraying, & surfacing

operations.

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 Kahoot.it

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