Plasma Arc Machining

Prof. Sachin N. Sawant

Transferred Arc Torches
• Cutting torch

• Single flow torch

• Dual flow torch

• Multiport nozzle torch

• Oxygen plasma cutting torch

• Welding torches

• Micro or needle torches

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Single Flow Torch
• Consists of disk shaped ,tapering cathode .

• Throat length of nozzle is 3mm to 5mm.

• High flow rates of gas.

• High velocity of flame.

• Suitable for cutting steels,aluminium & copper.

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Dual Flow Torch
• Dual gas plasma cutting systems usually use nitrogen as the
primary gas for both generating the plasma and protecting the
electrode and variety of secondary shielding gas

• An additional shield gas flow surrounding the main arc is

provided.

• Oxygen for steel, corbondioxide for stainless steel, argon

hydrogen mixture for aluminum

• Nozzle is kept inside the ceramic cup to avoid double arcing

• In carbon steel cutting, the dual gas flow steam is of oxygen, so

that the plasma cutting is amplified by oxygen cutting to achieve
very high cutting speed.

• Gas flow shields workpiece.

• Sharp corners can be maintained on the top side of the cut edges
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Multiport Nozzle Torch
• The dual flow concept is used in a
different form by providing part of
the plasma gas as shielding flow
through small ports surrounding the
main orifice of the nozzle.

• This flow constricts the arc and also

shields the work piece.

• It has the nozzle with multiport, the

Gas flow shields the gap.
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Welding Torches

• Cathodes are of small

diameter.

• Nozzles are longer.

• Torches operate at low

velocity & minimum
turbulence so that the molten
metal is not thrown away.
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Micro or Needle Torch
• These are similar to welding
torches.

• Operates at low power rate

(1kw).

• Used for welding, cutting of foils

& wire

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Air Plasma Torch
• Air plasma torch uses compressed air as the gas that ionizes
and does cutting.

• The air to be used should be uncontaminated.

• The nozzle of this torch may result in premature failure

because of double arcing i.e arcing between the electrode and
the nozzle, and between the nozzle and the workpiece.

• Air plasma cutting results in a high degree of tapered

machined surface. Zirconium or hafnium (electrode life ~ 2 hr
of cutting time) are used as electrode material because of their
higher resistance to oxidation.

• Because of poor oxidation resistance, tungsten electrode does

not last for more than a few seconds.

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Oxygen Plasma Torch
• To avoid oxidation of electrode (or to enhance the life of the
electrode), oxygen injected torch uses nitrogen as the plasma
gas.

• Oxygen is injected downstream of the electrode. However, it

lowers down the nozzle life.

• This torch gives high MRR and poor squareness of the cut
edges.

• It is commonly used for mild steel plate cutting.

• The presence of oxygen in the air helps in increasing MRR in

case of oxidizable materials like steel.

• In case of certain ferrous metals, cutting speed is increased by

about 25%. It is possible because oxygen backs up.

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Water Injected Torch
• In water injected torch water (pressure ~ 1.2 MPa) is injected
(radially or swirling vertically) to constrict the plasma.

• A small quantity (about 10%) of water vaporizes. This thin

layer of steam constricts the plasma and also insulates the
nozzle. Nitrogen at about 1 MPa is used as the plasma gas.

• To avoid double arcing, the lower part of the nozzle is made

of ceramic.

• Water constriction helps in reducing smoke, enhancing

nozzle life, reducing

• HAZ, and limiting formation of oxides on the cut edges of the

workpiece. In some systems, shielding gas or water is given
swirling motion. As a consequence of this, plasma is also
forced to swirl.
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Water Muffler
• Water muffler (a device that produces a covering
of water around the plasma torch and extends
down to the work surface) helps in reducing
smoke and noise.

• Water mixed with a dye also absorbs part of the

ultraviolet rays produced in PAC.

• In some cases, a water table is also used to

reduce the level of noise and extent of sparks.

• Water below the workpiece quenches sparks and

damps sound level.

• Underwater PAC systems are also available which

effectively reduce the noise and smoke levels
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Orientation of Torches

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Cooling Mechanism
• Hot gases continuously comes out of nozzle so there are chances of its over
heating.

• A water jacket is used to surround the nozzle to avoid its overheating

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Gases used in PAM
• The choice of gases will depend upon the economics and the quality of cut edge desired.

• Aluminum & magnesium can be cut with nitrogen, nitrogen hydrogen mix or argon
hydrogen mix.

• Stainless steel (50mm thick) can be cut by nitrogen hydrogen mix.

• Carbon steel can be cut with oxygen.

• For heavier section a mixture of 65% argon and 35% hydrogen is used.

• Use of compressed air as cutting gas is so much economical but operating life of
electrode designed for air cutting is too short for most users.

• The most successful approach to the use of an oxidizing cutting gas is to use nitrogen
as a plasma gas and subsequently introduce oxygen into it plasma downstream
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Parameters affecting the performance of torch
• Cathode size.

• Anode (nozzle) convergence.

• Nozzle orifice diameter

• Orifice length

• Electrode gap.

• Cooling of electrodes.

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Process performances
• Surface Speed: MRR starts increasing then start decreasing

• Max Cut Thickness 150 mm

• Cutting Speed S = Ф (thickness of material, Current and material type

• Poor Tolerance

• High width of cut 2.5 to 9 mm

• Taper: 5-70

• Surface Finish 5-75 micron

• HAZ (0.75 -5 mm)

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Operation data for Aluminum

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Operation data for Steels

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Applications
• In tube mill application.

• Welding of cryogenic, aerospace and high temperature corrosion resistant alloys.

• Nuclear submarine pipe system.

• Welding steel Rocket motor case.

• Welding of stainless steel tubes.

• Welding titanium plates up to 8mm thickness

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Applications
• Plasma arc process for cutting aluminum and other nonferrous materials was first introduced in
1955.

• The major areas of industrial production where plasma jets have successfully been employed are:

• Welding of material like titanium, stainless steel, etc. which are other-wise difficult to weld.

• Plasma arc surfacing.

• Plasma arc spraying.

• Sufficient literature on plasma arc welding is available but little information regarding plasma arc
surfacing and spraying exist.

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Applications
Plasma arc surfacing

• Surfacing is defined as the deposition of filler metal on metal surface to obtain

desired properties or dimensions.

• It is usually employed to extend the life of a part which may otherwise have all
the properties necessary for an engineering application, or to replace metal
which has worn out or corroded away

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Applications
Plasma Arc Spraying

• Spray coating is a process in which a surface of arbitrary thickness is obtained by spraying

the previously prepared surface of the base material with droplets of a molten material.

• Plasma spraying is a recent development in the field of metalizing and has been gaining
wider use as a method for producing surface coating of refractory materials and for
fabrication of free standing shapes.

• The utilization of plasma torches for spraying protective layers has brought about a rapid
progress in coating techniques.

• A higher operating temperature and the possible use of inert atmosphere are the main
advantages derived from this innovation

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Applications
Spray coating With Plasma

• The technique is similar to that of coating with oxy-fuel or electric arc metallizers.

• The process consists of two basic operations, the preparation of the surface to be coated
and spraying.

• The surface preparation is of the parent material. The surface of the parent metal is
cleaned by degreasing and appropriately roughened by grit blasting.

• Degreasing in a hot alkaline bath of trichloetrylene is indispensable if a part has been

contaminated with oil.

• In spraying with plasma guns, grit blasting will usually be sufficient because plasma
produces coating with very good adhesion.
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Control of Process Variables
• Torch to work distance affects power dwell time, velocity, impact density, substrate temperature,
deposition efficiency, oxidation, particle adhesion, coat bonded strength and stress in in the substrate
and coating.

• The rate of torch traverse affects the degree of oxidation of the coating sub layers and determines the
amount of thermal stresses in the coating

• A 90o torch to work angle may not always produce best results. A slightly offset position of the torch
prevents particle bound back provides a more desirable directional exhaust and takes advantages of
directional surface roughening for better mechanical bonding.

• Oxidation of the coating may be controlled by the use of an inert gas surroundings the torch impact
work area.

• The ratio of electric power to the gas flow rate determines the heat content of the plasma stream, the
velocity of the stream and melting and deposition potential of the torch.

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Advantages and Disadvantages
Advantages Disadvantages

• It gives faster production rate. • Its initial cost is very high.

• Very hard and brittle metals can be • It is uneconomical for bigger cavities
machined. to be machined.

• Small cavities can be machined with • Inert gas consumption is high.

good dimensional accuracy

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 Sli.do

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