FULLY AUTOMATED PLASMA TRANSFERRED

ARC POWDER DEPOSITION FOR WEAR AND

CORROSION RESISTANT OVERLAYING NEEDS
AN OVERVIEW

C.BALASUBRAMANIAN
OMPLAS SYSTEMS

About the Plasma Arc..

Plasma is the fourth state of matter, namely

ions. Gas particles exist in the form of ions
which conduct electricity
We make very effective use of this and
hence, called Plasma Arc.
For all practical purposes, this is a modified
Tungsten arc which is more directive,
columnar and stable. This is achieved by
constricting the tungsten arc through a
water cooled orifice.

TIG and PLASMA arc

TIG

PLASMA

Arc shapes in TIG and Plasma

Advantages of Plasma Arc over

TIG

Highly stable and concentrated arc

Heat less affected in the changes in the arc
length- More consistent.
Stable at very low welding currents
Very low heat input to the base metal (more
concentrated in a small area)
Flash light effect (with very powerful UV
radiation)
Very favorable shape to control the width to
penetration ratio.

Plasma Arc welding applications..

Metal cutting
Welding (key hole square butt welding)
Micro plasma welding (for thin sheets)
Weld overlaying
Plasma heat treatment (plasma nitriding,
heating)
Plasma metal spraying

Weld overlaying an important

tribological process..

Cladding of special material on the surface of

a component to obtain certain desired
properties that are not possessed by the core
or the base material itself. Because of these
special properties, the basic component
attains higher wear and corrosion resistance,
which increase the life of the component. In
simple words, part with inferior base material,
along with the overlay performs better than
either of the two for the given application.
This phenomenon can be at various operating
temperatures (cold or hot)

Plasma Weld overlaying using

powdered filler metal

Adding a homogenous powdered super alloy

through the plasma arc and deposit over a
substrate by melting both in a controlled
manner to obtain an effectively fused cladding
over the substrate.
The deposited metal is metallurgical bonded
with the base (not just sprayed )
Bonding strength is more than the strength of
the base metal in PTAW process.

Schematic of the Plasma weld

overlaying torch.

Parameters controls

PLC programs/ memories

Arc link communication systems for effective
co-ordination of modules through PCs
User friendly MMI (Man-Machine- Interface)
Specific PLC/CNC based systems to closely
monitor and control the WPS essential
variables (welding parameters, weld
sequencing, varying welding parameters
within a layer, etc)

Modules of fully automated PTAW

overlaying set up.

Plasma Transferred Arc Power source

Pilot Arc Power source
Welding Torch Carriage/ Manipulator (C&B)
Welding Positioner
Welding Torch weaving unit (Oscillator)
Plasma welding torch
X-Y-Z slides
Powder feeding unit/ wire feeding unit
Gas and control console
Operators control panel
Water cooling unit
AVC unit (optional)
Tracking devices (Optional)
Video /defect Monitors (Optional)

CARRIAGE TYPE SYSTEM

COLUMN & BOOM TYPE SYSTEM

Deloro machine Column & boom type

Deloro machine - Lathe type

Robotic PTAW overlaying system

Plasma Weld Overlaying torches

Deloro- ID torch

Plasma weld overlaying torches for

internal cladding
PLASMA WELD-OVERLAYING POSSIBLE
OVERLAYING OF INNER DIAMETERS OF SLEEVES
ABOVE 60MM WITH POWDER CONSUMMABLES.

PLASMA OVERLAYING IN
PROGRESS

PTAW weld overlaying - Description

Powdered consumable is introduced in the steady,

constricted columnar plasma transferred arc.
Pilot arc is generated inside the torch which provides
the ionization path for the transferred arc.
Argon gas from the cylinder is trifurcated in to three
parts, namely centre (plasma gas), shield gas and
powder carrier gas. Gas flows are rightly chosen to
get the right weld bead and chemistry.
Job is held in a positioner or turn table and rotated
at a desirable speed.
Powder feeder unit feeds the powder at a desirable
consistent feed rate (typical feed rate is 25 gms to 35
gms per minute).

Description continues.

Torch oscillator weaves the torch to get a right bead shape

(width and height).
Water cooling unit protects the torch by instantly cooling the
orifice and there by ensuring uninterrupted welding.
Basic carriage or the manipulator and the X-Y-Z slide are
used to precisely position the torch over the weld zone.
Operator panel provides all the salient controls which are to
be adjusted to get the right weld. It is linked to the control
console which interfaces all the modules.
Welding torch is specially designed for overlaying application
and there are various versions to suit various applications.
All the variables are set to attain the required melting of the
base and bead width & height (dilution not exceeding 5%)

Alloys deposited ..

All kinds of Cobalt based super alloys (Stellite of various

grades. etc.).
All kinds of Nickel based super alloys (Ni-Cr-B
colmonoys, Inconels, Monels, Hastelloy, Pure Nickel,
etc.)
All kinds of Stainless Steels (austenitic, ferritic and
martensitic)
Triboloy and other Lave Phase alloys
WC with Nickel or Cobalt matrix.
Chrome carbides in Iron matrix

and much more..

Sizes and shapes of the

components..

As small as 50 grams to unlimited sizes

Any regular shapes CYLINDRICAL SURFACES
(RODS, PIPES, RINGS), PLATES OF VARIOUS
THICKNESSES, CONICAL SHAPES, SPHERICAL
SURFACES, COMBINATION OF ALL SHAPES.
Irregular shapes are effectively handled by
Robots
Deposition up to 100 kgs. in a single component
with least interruption.

Challenges faced in Weld

overlaying

Cracks
Other weld defects such as porosities,
pinholes.
Crater shrinkages
Lack of fusion
Dilution with the base ( Fe% in the
deposit, strictly restricted to 7% max.)
DISTORTION

How these problems are effectively

tackled in PTAW.

Weld speeds far higher

Close adherence to WPS/PQR parameter machine
dependent Better arc heat control
Less welder/Operator influence
Less fatigue ( less deterrent to following the
parameters such as pre heating)
High pre heating levels ( up to 650 deg. C) with least
operator fatigue.
Greater uniformity of the temperature distribution. (dT
variations far less)
Automation aiding the best sequencing of weldingmultiple passes with weaving.

Merits of fully automatic PTA powder

deposition process over other
processes.

Highly energy density in a stable and focused arc gives

a better controlled and consistent weldment with
fusion bonding.
Long and uninterrupted arcing hours with least operator
fatigue.
Excellent weld appeal (resulting in low machining
requirements.)
Low and controllable dilution from the base metal
substrate Typically 5% without the fear of lck of
bonding.
Less defects ( porosity, crack, LOF, etc.)
High deposition rates (high productivity)

Merits continued

Close and accurate control of deposit thickness

(thicknesses from 1mm to 6mm is possible in
single layer- best is 3 to 4mm in single layer)
Highly versatile for automation because of
stable arc (hence, becomes a very effective
process on productivity and quality
parameters).
Good control on alloy chemistry (no variations
in the properties of the deposit) -close control
over parameters.
Great reproducibility / repeatability

Some applications..

Let us quickly go through some of the

applications which have been effectively
cladded using this process.
These are just a few examples and not
limitations, in any manner.
We an innovative approach, many
applications can be brought to the folds
of this process to have the best of its
advantages.

INC.625 OVERLAY OF FINSTOCK- FOR

INDIAN NAVY.
VIDEO1

PUMP SLEEVE
COLMONOY -5
CLADDED

PLUG VALVE
PLUG- STELLITE 6
CLADDED

HIGH PRESSURE
VALVE DISCSTELLITE6
CLADDED

ID CLADDING OF A
CONTROL VALVE
SLEEVE

AUTOMATED BALL
CLADDING

SLURRY VALVE PROFILE

DISC CLADDING- FULL
SEQUENCE AUTOMATED
VIDEO2

IMPORTANT ASPECTS TO SEE

ARC - THE TORCH, ANGLE, POSITION AND ITS

HEALTH
POWDER FEEDER SETTINGS
GAS SETTINGS
OSCILLATOR
WELD SEQUENCE
PRE HEATING AND PRE HEAT MAINTENANCE
WATER COOLING SETTINGS TORCH & JOBS

THE TORCH AND THE ARC.

ARC CONSTRICTION CONTROL, THE KEY TO GOOD WELD.

- TUNGSTEN ELECTRODE CENTRING
- ORIFICE 4.6 TO 5.0MM ( RE DRILL AND RE-FACE)
- SET BACK 2MM (DEPENDS ON ORIFICE)- BIGGER THE
ORIFICE LESSER THE SETBACK.
-GRINDING THE ELETRODE AND REFIXING, ONCE IN A SHIFT
- CLEANING THE ORIFICE AND REFI, ONCE IN A SHIFT
MONITOR HEALTHY PILOT ARC.
COOLING OF NOZZLE IN 10 SECS (AFETR SWITCHING OFF
THE PILOT ARC).

NO FEATHERY ARC..

TORCH POSITION SO IMPORTANT!

10MM STICK OUT

CENTRE OFF SET FOR CYLINDRICAL JOBS.
TORCH FOCUSING TOWARDS THE CENTRE (AXIS) FOR
CYLIDRICAL JOBS.
TORCH INCLINATION FOR THE MULTILAYER WELDING
TO FUSE THE CORNER (PERPENDICULAR TO THE WELD,
PARALLEL TO THE SHIFT DIRECTION).
SHIFT DISTANCE PROPORTIONAL TO THE BEAD WIDTH
AND THE HEIGHT ( CONTROL OVER THE ROTATION OF
THE KNOB EXACTLY), BASE METAL TEMPERATURE,
OTHER WELDING PARAMETERS.

THE POWDER
FEEDER..

GRAVITY ROTARY DRUM.

MAIN PORT SETTING - UNALTERABLE
SPEED OF THE DRUM ROTATION DECIDES THE GRAMMAGE
TWO OUTLET EQUAL DIVISION FOR GENERAL TORCHES
HIGH PERFORMANCE
SINGLE OUTLET FOR ID TORCHES
OPTIMUM FEED RATE 25 TO 35 GRAMS/MIN.
POWDER GAS - 2 TO 3 LIT PER MIN.(FOR SPHERICAL ARGON
ATOMISED POWDER, MAY VARY FOR OTHER POWDERS).
SEALING 100% REQUIRED. PERIODICALLY CHECK THIS
AFETR INSTALLTION- O RINGS CONDITION.
CHECK FOR POWDER SPRAY ANGLE AT THE TORCH ORIFICE,
EVRY TIME ON DOUBTS.

GAS SETTINGS

AS STATED IN WPS VERY IMPORTANT.

CENTRE- 2 TO 3 LPM, POWDER 2 TO 3 LPM, SHIELD 9 LPM TO 11 LPM.
CENTRE GAS FLOW INCREASES WITH INCREASING DIA OF THE ORIFICE PROPORTINAL
TO THE CROSS SECTION AREA.
GAS PURITY IS VERY IMPORTANT FOR WELD FINISH AND DEFECT FREE WELDS
PURE ARGON COMMERCIAL QUALITY
OTHER IMPURITIES OXYGEN, NITROGEN, ETC. ALL IN PPM LEVELS.
REGULATOR PRESSURE SETTING 1.0 TO 1.5 KGS/SQ.CM (15 PSI TO 20 PSI). MORE
THAN THIS GAS WILL BE WATSED.
CHECK FOR GAS LEAKAGES PERIODICALLY.
ONE CYLINDER OF 7 CU. M SHOULD WELD AROUND 6KGS.

7 CM = 7000 x1000 CC = 7000 x 1000 CU. ML = 7000 LITERS

THE USAGE = 3 + 3 + 10 = 16 LITRES PER MIN
THIS MEANS 7000/16 = 435 MIN. OF ARCING. THIS AGAIN
MEANS
30 x 435 = 6.9 KGS.
WITH OPERATIONAL EFFCIENCY AROUND 6 Kgs. PER CYLINDER.

Oscillator.
To be set to get the require width of the land up to 25
mm. (full bead width up to 25 mm deposit width)
For more than 25 mm multi passes. (each pass 8 to 10mm
with 35 to 40% overlap on the side)
The pitch of the overlap decides the amount of base
metal melting and hence the dilution and fusion.
The pitch of the overlap also decides the bead height
effectively and the inter bead level. This has to be set
for less than 0.3 mm.
The oscillator speed has to be set for 1 to 1.5mm bead
ripples ( this is done in relationship with the positioner
speed)
TORCH CLAMPS SHOULD BE STEADFAST TO AVOID MULTIPLE
ZIG-ZAG WEAVING.

WELD SEQUENCE.MULTIPASSES

PRE HEATING AND PREHEAT

MAINTENANCE..

DONE TO REDUCE THE DELTA T FACTOR AND THERE BY

GIVE THE DEPOSIT A COMPRESSIVE LOAD. THIS WILL AVOID
CRACKS
UNIFORM HEAT DISTRIBUITION ON THE JOB
DONE FOR ALL ALLOYS EXCEPT SS
FOR CARBON STEELS OVER 25MM THICKNESS
WELDING OVER HF MATERIAL (STELLITE OR COLMONOY
CALLS FOR HIGHER PREHEAT)
CHECK THE WPS FOR PREHEAT TEMPERATURES AND SEEK
GUIDANCE.
STELLITE CRCKS ARE 90% DUE TO LACK OF PREHEATING AND
PRE HEAT MAINTENANCE
THE JOB HAS TO BE COOLED IN WORMICULITE SAND TO
AVOID NON-UNIFORM CONTRACTION

WATER CHILLER SETTINGS

THIS HAS TO BE SET TO AVOID WATER

SWEATING IN THE TORCH AND AT THE
SAME TIME EFFECTIVE COOLING.
OPTIMUM SETTING IS 22 DEG. C OR 23
DEG.C.
FLOW RATE DESIRABLE IS MIN. 6LPM AT
THE RETURN WATER END.
FLOW SWITCH IS MANDATORY TO AVOID
TORCH BURNING OR DAMAGE

The facts prove..

That PTAW weld overlaying process is a very effective
method to get thick claddings.
This high energy arc welding process used in automation
delivers excellent and accurate fusion bonded weld
overlays coupled with lowest possible dilution and very
good weld appeal, compared to other welding processes,
IF WE SET THE MACHINE VARIABLES PROPERLY.
It can be very disastrous if NOT handled properly.
Proper observation teaches you all.. To be very
effective.
BE READY FOR THE EXPERIMENTATION AND CONTINUOS
LEARNING.
UNNAL MUDIYUM THAMBI