Equipment for Plasma Welding

Plasma welding derives its unique operating characteristics from the torch design. As in TIG welding, the arc is formed between the end of a small diameter tungsten electrode and the workpiece. However, in the plasma torch, the electrode is positioned behind a fine bore copper no le. !" forcing the arc to pass through the no le, the characteristic columnar #et, or plasma, is formed. As described in $ob %nowledge for &elders, 'o (, three different operating modes can be produced b" the choice of the no le bore diameter, current level and plasma gas flow rate) Microplasma *+., to ,-A. is equivalent to microTIG but the columnar arc allows the welder to operate with a much longer arc length. The arc is stable at low welding current levels producing a /pencil0like/ beam which is suitable for welding ver" thin section material. Medium current plasma *,- to ,++A. similar to conventional TIG, is also used for precision welding operations and when a high level of weld qualit" is demanded. Keyhole plasma *over ,++A. produced b" increasing the current level and the plasma gas flow. It generates a ver" powerful arc plasma, similar to a laser beam. 1uring welding, the plasma arc slices through the metal producing a ke"hole, with the molten weld pool flowing around the ke"hole to form the weld. 1eep penetration and high welding speeds can be achieved with this operating mode.

As the plasma arc is generated b" the special torch arrangement and s"stem controller, the equipment can be obtained as an add0on unit to conventional TIG equipment to provide additional pilot arc and separate plasma and shielding gases. Alternativel", purpose0built plasma equipment is available. 1espite similarities in plasma and TIG equipment, there are several important differences in the following components) power source torch backing s"stem protective equipment

Power source
The power source for plasma welding is almost e2clusivel" 13 and, as in TIG, the drooping, or constant current, output characteristic will deliver essentiall" constant current for a given power source setting. The power source is ideal for mechanised welding as it maintains the current setting even when arc length varies and, in manual welding, it can accommodate the natural variations of the welder. The plasma process is normall" operated with electrode negative polarit" to minimise heat produced in the electrode *appro2imatel" ,45rd of the heat generated b" the arc is produced at the cathode with 645rds at the anode.. 7pecial torches are available, however, for operating with electrode positive polarit" which rel" on efficient cooling to prevent melting of the electrode. The positive electrode torch is used for welding aluminium which requires the cathode to be on the material to remove the o2ide film. A3 is not normall" used in the plasma process because it is difficult to stabilise the A3 arc. Problems in reigniting the arc are associated with constriction b" the no le, the long electrode to workpiece distance and balling of the electrode caused b" the alternate periods of electrode positive polarit". The square wave A3 *inverter, switched 13. power source, with an efficientl" cooled torch, makes the use of the A3 plasma process easier8 rapid current switching promotes arc reignition and, b" operating with ver" short periods of electrode positive polarit", electrode heating is reduced so a pointed electrode can be maintained. The plasma s"stem has a unique arc starting s"stem in which H9 is onl" used to ignite a pilot arc held within the bod" of the torch. The pilot arc formed between the electrode and copper no le is automaticall" transferred to the workpiece when it is required for welding. This starting s"stem is ver" reliable and eliminates the risk of electrical interference through H9.

Torch
The torch for the plasma process is considerabl" more comple2 than the TIG torch and attention must be paid, not onl" to initial set up, but also to inspection and maintenance during production.

Nozzle
In the conventional torch arrangement, the electrode is positioned behind the water cooled copper no le. As the power of the plasma arc is determined b" the degree of no le constriction, consideration must be given to the choice of bore diameter in relation to the current level and plasma gas flow rate. 9or a /soft/ plasma, normall" used for micro and medium current operating modes, a relativel" large diameter bore is recommended to minimise no le erosion. In high current ke"hole plasma mode, the no le bore diameter, plasma gas flow rate and current level are selected to produce a highl" constricted arc which has sufficient power to cut through the material. The plasma gas flow rate is crucial in generating the deepl" penetrating plasma arc and in preventing no le erosion8 too low a gas flow rate for the bore diameter and current level will result in double arcing in the torch and the no le melting. The suggested starting point for setting the plasma gas flow rate and the current level for a range of the bore diameters and the various operating modes is given.

Electrode
The electrode is tungsten with an addition of between 6 and -: thoria to aid arc initiation. 'ormall", the electrode tip is ground to an angle of ,- degrees for microplasma welding. The tip angle increases with current level and for high current, ke"hole plasma welding, an angle of ;+ degrees to <+ degrees is recommended. 9or high current

levels, the tip is also blunted to appro2imatel" ,mm diameter. The tip angle is not usuall" critical for manual welding. However, for mechanised applications, the condition of the tip and the no le will determine the shape of the arc and penetration profile of the weld pool penetration, so particular attention must be paid to grinding the tip. It is also necessar" to check periodicall" the condition of the tip and no le and, for critical components, it is recommended the torch condition is checked between welds.

Electrode set-bac
To ensure consistenc", it is important to maintain a constant electrode position behind the no le8 guidance on electrode set0back and a special tool is provided b" the torch manufacturer. The ma2imum current rating of each no le has been established for the ma2imum electrode set0back position and the ma2imum plasma gas flow rate. =ower plasma gas flow rates can be used to soften the plasma arc with the ma2imum current rating of the no le providing electrode set0back distance is reduced.

Plasma and shielding gas

The usual gas combination is argon for the plasma gas and argon06 to >: H6 for the shielding gas. Irrespective of the material being welded, using argon for the plasma gas produces the lowest rate of electrode and no le erosion. Argon 0 H6 gas mi2ture for shielding produces a slightl" reducing atmosphere and cleaner welds. Helium gives a hotter arc8 however, its use for the plasma gas reduces the current carr"ing capacit" of the no le and makes formation of the ke"hole more difficult. Helium 0 argon mi2tures, e.g. (-: helium 0 6-: argon, are used as the shielding gas for materials such as copper. Plasma gas flow rate must be set accuratel" as it controls the penetration of the weld pool but the shielding gas flow rate is not critical.

!ac ing system

The normal TIG range of backing bar designs or shielding gas techniques can be emplo"ed when using micro and medium current techniques. &hen appl"ing the ke"hole mode a grooved backing bar must be used, with or without gas shielding or total shielding of the underside of the #oint. !ecause the efflu2 plasma normall" e2tends about ,+mm below the back face of the #oint, the groove must be deep enough to avoid disturbance of the arc #et8 if the efflu2 plasma hits the backing bar, arc instabilit" will disturb the weld pool, causing porosit".

Protecti"e equipment
Protective equipment for plasma welding is as described for TIG in $ob %nowledge for &elders 'o ,(. ?egarding protection from arc light, a similar 7hade number to TIG at the same welding current level should be used in head or hand shield. The glass will be slightl" darker than that used for @@A welding at the same current level. ?ecommended shade number of filter for plasma welding) #hade Nunber Micro Plasma Plasma +.- to , ; , to 6.( 6.- to > - to ,+ < ,+ to ,,+ ,- to 5+ ,, 5+ to ;+ less than ,-+ ,6 ;+ to ,6,-+ to 6-+ ,5 ,6- to 66above 6-+ ,A 66- to A-+ 7ee !7 ;5<),<>< for further information on shade numbers. !ack to the $ob %nowledge inde2
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