IPE 3105

Modern Machining Process

PLASMA ARC MACHINING (PAM)

Sheikh Salman
Lecturer, MPE, AUST
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• Plasma is the fourth state of

What is matter.
• When the temperature of a gas is
Plasma?? raised to about 2000°C, the gas
molecules become dissociated into
separate atoms. At higher
temperatures (30,000°C), these
atoms become ionized. The gas in
this stage is termed plasma.
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Plasma Arc Machining (PAM)

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

Plasma becomes electrically conductive

Employs a high velocity jet of high temp. plasma gas

which are directed to workpiece
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Plasma Arc Machining (PAM)

1 The temperature of plasma can be of the order of 33,000°C. Work

piece material melts out and vaporizes due to this high temperature.

2 Some materials (like- Al, SS) have high thermal conductivity, large
heat capacity and good oxidation resistance.

3 These can be easily cut by plasma arc machining (PAM).

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Working Principle
PAM employs a high velocity jet of high-temperature gas to melt and displace material

Schematic illustration of the plasma arc machining process

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Working Principle
A continuous arc is generated between a hot tungsten
cathode and the water-cooled copper anode

A gas is introduced around the cathode and flows through the anode

An inert gas-flow surrounding the main flame is provided to shield

the machining gas from the atmosphere

The temperature reaches 28,000°C in the narrow orifice around the

cathode, which is enough to produce a high-temperature plasma arc
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Working Principle
The plasma arc is forced through the compressed zone of the nozzle
duct towards the workpiece

This results in almost high exit gas velocity and high core
temperature

Plasma jet melts the workpiece material and the high-velocity gas
stream effectively blows the molten metal away

The depth of heat affected zone depends on the work material, its
thickness and cutting speed
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Plasma Arc Machining (PAM)

https://www.youtube.com/watch?v=f5TwzRW_DtY
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PAM Arc System

Transferred Plasma Arc system Non-Transferred Plasma jet system

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PAM Arc System

Transferred Arc Non-transferred Arc

➢ Arc is between electrode and workpiece ➢ Arc is within the torch itself
(Electrode and nozzle)

➢ Heat from anode and plasma ➢ Heat is only from plasma

➢ High process efficiency ➢ Low process efficiency

➢ Higher energy transfer ➢ Less energy transfer

➢ Higher penetration ➢ Less penetration

➢ Suitable for welding operation ➢ Suitable for cutting operation

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Major Components
▪ Power supply
▪ Gas supply - higher the gas flow rate higher the momentum of the plasma jet
▪ Cooling water system
▪ Plasma torch

❑ Carbon alloy and cast steels are cut with mixture of N2 and H2 (the compressed
air)
❑ SS, Al, and other non ferrous alloys are cut with Ar, N2 and H2
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Plasma Torch
➢ Electric arc constricts from nozzle,
generates basic plasma jet
➢ Instead of diverging into open arc, the
nozzle constricts arc into a small cross
section

Cross Section view of Plasma Torch

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Plasma Torch
Classification of Plasma Arc:

1 Air plasma torch

2 Dual gas plasma torch

3 Water injected plasma torch

4 Oxygen injected plasma torch

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Air Plasma
• Nozzle torch may face premature failure due to double
arcing (electrode & nozzle and nozzle & workpiece)
• Main drawback is the heavily oxidized surface, which is
frequently obtained in case of SS and Al.
• Electrically conductive materials such as SS and Cr-Ni
alloy steels, aluminum, and copper can be machined.
• High degree of tapered machining surface can be
produced.
• The machining cost is about half that of gas or water, due
to using air.
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Dual Gas Plasma

• Tungsten electrode is used
• Uses additional outer shield gas around nozzle to reduce
the effect of atmosphere on cutting gas
• Cutting gas is usually nitrogen or argon
• Shield gas is chosen based on work metal being cut
• Examples: hydrogen for SS, Al and other non-ferrous
metals; CO2 for ferrous and non-ferrous metals; air or
oxygen for mild steel
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Water Plasma
• Nitrogen is used as cutting gas.

• Shield gas is replaced with water. Water forms a

radial jacket around the plasma torch.

• In order to avoid double arcing, ceramic is used at

the lower part of the nozzle.

• Cooling effect of water reduces width of cutting

zone and improves quality of cut.

• Water reduces smoke, enhances nozzle life and

reduces HAZ.
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Oxygen Injected Plasma

• Oxygen is used as a shielding gas and it is injected at the
downstream of the electrode.
• Nitrogen gas is used as plasma (cutting gas) and
enhances the life of electrode.
• For ferrous material oxygen increases machining
efficiency.
• High MRR is obtained.
• Oxygen lowers the nozzle life.
• Commonly used for mild steel plate cutting.
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Process Parameter
• Operation aspect: ➢ Transferred (PAM)

➢ Non-transferred Modes (PJM)

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Process Parameter
• Design aspect: ➢ Gas flow rate

➢ Nozzle orifice diameter - 1.5 – 8 mm (larger size for

grooving)
➢ SOD gap

➢ Cooling of electrode
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Process Capability Velocity of

plasma jet
500 m/s
• Plasma gas MRR
Maximum
➢ Argon and hydrogen (65-35 mixture) plate thickness 150 cm³/min
200 mm
➢ Nitrogen and hydrogen (80-20 mixture)
Voltage
➢ Nitrogen and oxygen (80-20 mixture). 30-250V
➢ Range of flow rate: 2 – 12 m3/hr. Current
Specific
energy up to 600A
100 W/ (cm³-
• Electrode material min)
➢ Tungsten Power range
2-200kW
➢ Copper hafnium or copper zirconium (in air
plasma machining)
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Mechanism of Material Removal

Due to the high

concentration of the
An inert gas is blown energy in a limited
at high speed out of a space, the material of
nozzle the workpiece is
An electrical arc is warmed till the
formed through The melted material
melting of a layer
that gas from the is removed from the
nozzle to the cut by the plasma jet
surface being cut
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Material Removal Rate

• In optimum plasma operation, of all the electric power fed to the torch:

➢ up to 45% can be used to machine material

➢ about 10% is used by the cooling water in the plasma equipment

➢ remainder is lost in the hot gas and work material.

Higher MRR is obtained usually!!

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Material Removal Rate

Effect of power on removal rate (surface speed: 2.1 m/min)

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Material Removal Rate

• Maximum MRR 150 𝑐𝑚3 /min has been reported (input power 50 kw).
• In PAM, the angle of incidence of plasma on workpiece, work material surface
condition and gas flow rate are also important.
• Material removal rate also depends on cutting speed. If cutting speed increases, MRR
initially increases to a maximum value but reduces then on.
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Accuracy and Surface Quality

• The high machining speed does not allow the heat to penetrate more than a few microns
from the edges of the cut which produces little or no distortion in the cut workpiece.
• The cutting edge of the material tends to be harder than the base material.
• Additionally due to the rapid cooling, cracks may arise beyond the heat-affected zone to 1.6
mm.
• Comparatively higher heat-affected zone (HAZ) is obtained.
• A clean, smooth surface is produced by PAM.
• Large tolerances of ±1.6 mm can be achieved.
• Finish cuts are required for narrow tolerances.
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Characteristics of PAM

• Metal removal technique: Heating, melting, and vaporizing

by using plasma.
• Work material : All materials that conduct electricity.
• Tool: Plasma jet
• Velocity of plasma jet: 500 m /s
• Power range: 2 to 220 kW
• Current: As high as 600 amp.
• Voltage : 40 – 250 V
• Cutting speed: 0. 1 to 7 m / min
• Metal removal rate: 145 cm3 /min
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Advantages
• Cutting metal profile such as stainless steel, titanium, Aluminium alloy and copper alloy
(difficult to cut using oxy-gas techniques)
• Cutting refractory materials
• Rough turning of nickel alloy or other difficult to machine materials
• Forming grooves
• Drilling holes
• Apart from machining, plasma arc is also used in welding.
• Non-transferred arc is also used in spraying paint on ceramics and to coat metal with ceramics
• Ferrous and non-ferrous materials up to 200 mm thick can be cut
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Limitations
• Main disadvantage of PAM/PJM is high electric power requirement.
• Circular holes can be drilled but size limited by nozzle size.
• Another minor drawback - plasma arc typically leaves a 4-6 degree bevel on the cut edge,
although this angle is almost invisible on thinner material, it is noticeable on thicker
pieces.
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Applications
• This is chiefly used to cut stainless steel and Aluminium alloys.
• Profile cutting and grooving operation of metals have been the common prominent
commercial application of PAM.
• On the machining side, plasma has been used successfully in conventional turning and
milling of very difficult materials.
• A plasma arc can cut tubes of wall thickness of up to 50 mm.
• The process is recommended for parts that have subsequent welding operations.
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