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Introduction of Plasma
The plasma arc employs a restricted arc through
which a selected gas is made to flow. Plasma is generated by exposing a gas stream to the electrons from an electric arc. High velocity electrons generated by the arc impact gas molecules, and ionize them. The gas is forced through the nozzle, and the jet heats the metal, and blasts the molten metal away.
electrode and the while the plasma gas is flowing, the gas is ionized and becomes conductive, then a plasma arc is generated. Since
The plasma arc is restricted by the nozzle, it
had higher energy density, compared to MAG and TIG and can be used as a heat source of ultra high temperature (above 20,000C) having high heat concentrating performance.
this configuration the maximum cathode amperage is about 3 000 A, at a voltage of 200 V the maximum electrical power input would be 600 kW.
Gases Use
Primary Gases:
Gases that are used to create the plasma arc. Examples are nitrogen, argon, hydrogen, hydrogen, or mixture of them
1. Transferred Arc
The generated arc is between the electrode and the work-piece.
2. Non transferred
Arc
The generated arc is between the electrode and the nozzle and heat is carried to the work-piece by the plasma gas
Transfer arc
(paw) terminology
ORIFICE GAS:
This gas, referred to earlier as carrier gas, is an inert gas which is fed through the torch to surround the electrode and to enter the arc through the plenum chamber.
PLENUM CHAMBER:
This has been referred to under orifice gas.
SHIELDING GAS:
The shielding gas is provided additionally through the outer gas nozzle , in the same manner as in TIG PROCCES. To protect the area of the work piece , over which the arc plasma impinges. Its composition is the same as the orifice gas, i.e argon or argonhelium mixture.
Nozzle
The nozzle, sometimes called the cup, is made of ceramic or any other high-temperature-resistant substance. This helps prevent the internal electrical parts from accidental shorting and provides control of the shielding gas or water injection if they are used.
Figure 1. Plasma arc welding: (a) overall process (b) welding area enlarged and shown with key holing.
properties
specification
- Mechanics of material removal - melting - Medium - plasma - Tool - plasma jet - Maximum temperature = 16,000 - Maximum velocity of plasma jet = 500 m/sec - Maximum mrr = 150 cm3/min - Specific energy = 1000 W/cm3/min - Power range = 2 to 200 KW - Maximum plate thickness = 200 mm (depends on material)
specification
- Cutting speed = 0.1 to 7.5 m/min - Voltage 30 to 250 V - Current <= 600 A - Critical parameters - voltage, current, electrode gap, gas flow rate, nozzle dimensions, melting temperature - Materials applications - all conducting materials - Shape application - cutting plates - Limitation - Low accuracy
Wall-stabilized
designs
electrode the plasma gas. In the wall-stabilized arc the discharge fills the major portion of the internal nozzle tube space, and for large nozzle diameters the arc can be wall-stabilized only if very high currents and arc temperatures exist.
metals.
clean, Bright, and ready to be welded. Plasma arc gouging is especially. expensive compared to plasma arc gouging.
References
Miller Electric Mfg. Co. Plasma Cutting Buyers Guide. Illinois, 2004
A. Al-Shamma, R. Wyllie, J. Lucas, and J. D. Yan, Atmospheric Microwave Plasma Jet for Material Processing, IEEE Trans. on Plasma Science, Vol. 30, p.1863-1871, 2002.
S. Ramakrishan, M. Gershenzon, F. B. Polivka, T. N. Kearney, and M. W. Rogozinski, Plasma Generation for the Plasma Cutting Process, IEEE Trans. on Plasma Science, Vol. 25, p.937-946, 1997.
K. Richardson, B. Stein, P. Shah, and N. Isaacs, Process Development of Electrode-Tab Welds for Aerospace, Lithium-Ion Cells, IEEE Conference, Vol. 1, p.651-658, 2000.