The plasma welding process was introduced to the welding industry in 1964 as a method of bringing better control to the arc welding process in lower current ranges. Today, plasma retains the original advantages it brought to industry by providing an advanced level of control and accuracy to produce high quality welds in miniature or precision applications and to provide long electrode life for high production requirements

Principles of Operation of PLASMA ARC MACHINING :

The plasma arc welding process is normally compared to the gas tungsten arc process. But in the TIG-process, the arc is burning free and unhandled, whereas in the plasma-arc system, the arc is necked by an additional water-cooled plasma-nozzle.

A plasma gas – almost always 100 % argon –flows between the tungsten electrode and the plasma nozzle.The welding process involves heating a gas called plasma to an extremely high temperature and then ionizing it such that it becomes electrically conductive. 

The plasma is used to transfer an electric arc called pilot arc to a work piece which burns between the tungsten electrode and the plasma nozzle. By forcing the plasma gas and arc through a constricted orifice the metal, which is to be welded is melted by the extreme heat of the arc.

 The weld pool is protected by the shielding gas, flowing between the outer shielding gas nozzle and the plasma nozzle. As shielding gas pure argon-rich gas-mixtures with hydrogen or helium are used.

The high temperature of the plasma or constricted arc and the high velocity plasma jet provide an increased heat transfer rate over gas tungsten arc welding when using the same current.

This results in faster welding speeds and deeper weld penetration. This method of operation is used for welding extremely thin material and for welding multi pass groove and welds and fillet welds.

Uses & Applications of PLASMA ARC MACHINING 

Plasma arc welding machine is used for several purposes and in various fields. 

The common application areas of the machine are:

1. Single runs autogenous and multi-run circumferential pipe welding.

2. In tube mill applications.

3. Welding cryogenic, aerospace and high temperature corrosion resistant alloys.

4. Nuclear submarine pipe system (non-nuclear sections, sub assemblies).

5. Welding steel rocket motor cases.

6. Welding of stainless steel tubes (thickness 2.6 to 6.3 mm).

7. Welding of carbon steel, stainless steel, nickel, copper, brass, monel.

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