DELHI TECHNOLOGICAL UNIVERSITY

MANUFACTURING TECHNOLOGY (ME-208)

MTE- PROJECT
(PLASMA ARC WELDING)

SUBMITTED BY- ASHISH KUDIYAL(2K20/ME/54)

DEV SAGAR(2K20/ME/77)
SUBMITTED TO – PROF. VISHAV KAMAL
PLASMA ARC WELDING
◦ Plasma arc welding (PAW) is a form of arc welding that resembles gas tungsten arc welding (GTAW). An electric arc is generated
between a workpiece and an electrode. The main difference between PAW and GTAW is that the electrode is located within the torch's
shell, separating the plasma arc from the shielding gas envelope. The plasma is then pushed through a fine-bore copper nozzle, which
constricts the arc, resulting in high velocities (approaching the speed of sound) and temperatures approaching 28,000 °C (50,000 °F) or
higher as it exits the orifice.

A transient condition of a gas is arc plasma. Electric current flowing through the gas ionizes it, making it a conductor of electricity.
Atoms are broken down into electrons () and cations (+) in the ionized state, resulting in a mixture of ions, electrons, and strongly excited
atoms. The degree of ionization can range from 1 percent to more than 100 percent (possible with double and triple degrees of
ionization). As more electrons are taken from their orbits, certain states emerge. The electrical power used to produce arc plasma
determines the energy of the plasma jet and thus the temperature. A standard temperature in a plasma jet torch is about 28000 °C (50000
°F), compared to about 5500 °C (10000 °F) in a conventional electric welding arc. Both welding arcs are (partially ionized) plasmas, but
in plasma arc welding, the arc plasma is constricted. Plasma torches, like oxy-fuel torches, can be used for both welding and cutting.
WORKING PRINCIPLE
◦ This is an arc welding procedure in which a focused plasma arc is produced by the machine's high-
frequency device and guided towards the weld region. A low current pilot arc begins the plasma between
the tungsten electrode and the orifice. Since plasma arc welding is forced through a small orifice or
nozzle to increase pressure, temperature, and heat, it is concentrated. The arc will now become very
stable, with improved shape and heat transfer rate as a result of the above characteristic. The temperature
of the arc will reach 33,000°C, so the nozzle is surrounded by a water-cooling system to prevent it from
overheating and wearing out. Typical operating currents are less than 100 amps. This distinguishes
Plasma Welding from other forms of welding. Filler metal is inserted through the arc in the same way as
it is in Gas Tungsten-arc Welding. An outer shielding ring and the use of inert gases such as argon,
helium, or mixtures provide arc and weld-zone shielding.
EQUIPMENTS USED
◦ 1. POWER SOURCE
◦ 2. TORCH
◦ 3. NOZZLE
◦ 4. ELECTRODE
◦ 5. ELECTRODE SET-BACK
◦ 6. PLASMA AND SHIELDING GAS
◦ 7. BACKING SYSTEM
◦ 8. PROTECTIVE
1.POWER SOURCE
Plasma welding uses almost entirely DC power, and the drooping, or constant current, output characteristic, similar to TIG, can
provide essentially constant current for a given power source environment. The power source is suitable for mechanized
welding because it keeps the current setting even though the arc length changes, and it can accommodate the welder's normal
differences in manual welding. The electrode is usually operated with negative polarity to reduce the amount of heat produced
in the electrode (roughly 1/3 of the heat created by the arc is produced at the cathode, with 2/3rds at the anode).

2. TORCH
The plasma torch is much more complicated than a TIG torch, and special
attention must be paid not only to initial setup, but also to inspection and
maintenance during manufacturing.
3. NOZZLE
The electrode is placed behind the water-cooled copper nozzle in a traditional torch setup. Since the degree
of nozzle constriction determines the strength of the plasma arc, the bore diameter must be chosen in
relation to the current level and plasma gas flow rate. A relatively large diameter bore is recommended for
a 'soft' plasma, which is typically used for micro and medium current operating modes to reduce nozzle
erosion. The nozzle bore diameter, plasma gas flow rate, and current level are selected in high current
keyhole plasma mode to create a highly constricted arc with sufficient power to cut through the material.
The plasma gas flow rate is critical for producing the deeply penetrating plasma arc and preventing nozzle
erosion; if the gas flow rate is too low for the bore diameter and current level, the torch will double arc and
the nozzle will melt.
For a variety of bore diameters and operating modes, a suggested starting point for setting the plasma gas
flow rate and current level is given.
4. ELECTRODE
◦ The electrode is made of tungsten with a thoria content of 2 to 5% to aid arc initiation. For micro-plasma welding, the
electrode tip is typically ground at a 15-degree angle. The tip angle increases with current level, and an angle of 60
degrees to 90 degrees is recommended for high current, keyhole plasma welding. The tip is also blunted to around
1mm diameter for high current levels. For manual welding, the tip angle is normally unimportant. However, in
mechanized applications, the shape of the arc and penetration profile of the weld pool penetration are determined by
the condition of the tip and nozzle, so grinding the tip is critical. It is also appropriate to inspect the tip and nozzle on
a regular basis, and it is recommended that the torch condition be tested between welds for critical components.

5. ELECTRODE SET-BACK
Maintaining a consistent electrode location behind the nozzle is critical for consistency; the
torch manufacturer can provide instructions on electrode set-back as well as a special method.
For the maximum electrode set-back location and the maximum plasma gas flow rate, each
nozzle's maximum current rating has been determined. Lower plasma gas flow rates with the
nozzle's maximum current rating may be used to soften the plasma arc if the electrode set-
back distance is decreased.
6. PLASMA AND SHIELDING GAS
◦ The most common gas mixture is argon for the plasma gas and argon-2 to 8% H2 for the shielding gas. Using argon as the
plasma gas achieves the lowest rate of electrode and nozzle corrosion, regardless of the material being welded.
◦ Shielding with an Argon-H2 gas mixture results in a slightly reducing atmosphere and smoother welds. While helium
produces a hotter arc, its use as a plasma gas decreases the nozzle's current carrying ability, making keyhole formation more
difficult.
◦ For materials like copper, helium-argon mixtures, such as 75 percent helium and 25 percent argon, are used as shielding gases.
The plasma gas flow rate is important since it governs the weld pool penetration, but the shielding gas flow rate is not.

7. BACKING SYSTEM
When using micro and medium current techniques, the standard TIG set of backing bar
designs or shielding gas techniques can be used. A grooved backing bar must be used when
using the keyhole mode, with or without gas shielding or absolute shielding of the
underside of the joint. Since the efflux plasma usually extends about 10mm below the back
face of the joint, the groove must be deep enough to prevent arc jet disturbance; if the efflux
plasma collides with the backing bar, arc instability will disrupt the weld pool, resulting in
porosity.
WORKING PROCESS
◦ This welding is similar to TIG welding except that plasma is used to heat the parent material. The following is a summary of how it works:
◦ The work parts are first thoroughly washed. The power source generates an arc between the tungsten electrode and the nozzle, or the tungsten electrode and the
workpiece.
◦ The tungsten electrode produces a high-intensity arc that ionizes gas particles and transforms orifice gases to plasma. A small orifice delivers the hot ionized
gas to the welding plates.
◦ The shielding gases, such as argon, are delivered to the welding torch's outer nozzle through a pressure valve and a regulating valve. These gases form a
protective shield around the welding area, shielding it from ambient gases such as oxygen and nitrogen.
◦ The welding plates are struck by the plasma, which fuses them together. The welding torch is then pushed in the welding direction.
◦ The welder manually feeds filler material if the welding requires it.

TYPES-
Plasma arc welding process has two different modes that is:
1. Non-transferred arc mode: Current flows from the electrode within the torch to the nozzle
holding the orifice and back to the power supply in non-transferred arc mode. Plasma spraying is
done for it.
2. Transferred arc mode: Current is transferred from the tungsten electrode within the welding torch
through the orifice to the workpiece and back to the power supply in transferred arc mode. It's used
to join metals together.
DIFFERENCE B/W TRANSFERRED ARC AND
NON-TRANSFERRED ARC MODE
APPLICATIONS
 This method of welding produces quicker, more durable welds with lower heat production. It is
more versatile and can be used in more applications than the gas tungsten arc process because it
produces less heat. The 2-process option is one of the reasons plasma arc welding is so common
among commercial welders. For a non-transferred arc or a direct to target arc, a plasma arc
welder uses a watercooled flow. Plasma arc welding is a natural match for these applications on
the factory floor because of this.

1. MANUFACTURING STEEL TUBES

Steel tubes are an essential component of the exhaust system of automobiles. PAW is often used in the manufacturing process because it is
faster than GTAW systems, Penetrates nearly as well , Uses less filler.

2. WELDING SMALL METAL COMPONENTS

When working on small parts or making small welds on larger bits, PAW systems' keyhole setting comes in handy. Even on thicker steel pieces,
it can produce a strong seal in a single move.
3. BEST FOR BUTT JOINTS
Although laser beam welding is faster than PAW, the tolerance for joint misalignment is lower. GTAW systems produce high-quality
welds but are time-consuming to use. Welders gain more speed and the ability to make strong welds at joint sites with PAW.

4. WELDING THIN, ELECTRONIC CHIPS

PAW can operate at very low currents, making it ideal for applications involving delicate computer components. Since electronic
chips are sensitive to environmental factors such as heat, low current is especially useful in these applications. Although GTAW and
LBW are often used, PAW is the preferred method for precision welds.
5. MEDICAL DEVICE MANUFACTURE
Some medical devices have sealed components that can be damaged by excessive heat or noise. Due to its high-precision operations
and low dba performance, PAW is ideal for installing these components. It is still very noisy at up to 100 dba during high-current
operations, but it is almost quiet at low current.
FEATURES AND BENEFITS
◦ Plasma arc welding has a number of characteristics and advantages.
1. A shielded electrode is used in plasma arc welding, allowing for less electrode contamination. This is particularly useful when
welding materials that emit gas during the welding process, contaminating the unprotected GTAW electrode. Due to the arc form and
also heat distribution, plasma arc welding allows for arc length shifts. As a result, the arc standoff distances are not as important as they
are in GTAW. In 99 percent of applications, plasma arc welding produces good weld accuracy, and no AVC is needed, even when wire
feed is used.
2. Since the arc transfer is gentle and consistent, it can be used to weld thin sheet, fine wire, and miniature components that would be
damaged by a harsh GTAW arc launch. Welding with a stable arc eliminates arc wander so the arc welds where it is directed, allowing
weld tooling to be placed near to the weld joint for maximum heat sinking.
3. Plasma arc welding uses only a small amount of high-frequency noise to start the pilot arc, so it can be used with NC controls with
less concern about the arc starting noise causing electrical equipment glitches. Another advantage is in welding applications involving
hermetic sealing of electronic components, where the GTAW arc start may cause electrical disruptions, potentially damaging the
component's electronic internals.
4. Plasma welding uses three times the arc energy of TIG welding, resulting in less weld distortion and smaller welds at higher welding
rates. Welding times as short as 0.005 seconds are suitable for spot welding fine wires, while precise weld times combined with
precision motion devices allow seam welding to achieve repeatable weld start/stop positions. Welding of miniature components and
good control in down sloping to a weld edge are both possible with low amperage arc welding (as low as 0.05A). The arc diameter
selected through the nozzle orifice aids in predicting the size of the weld bead.