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LEARNING GUIDE

Week No.: __13__

TOPIC/S
 PLASMA-ARC WELDING PROCESS (PAW)

EXPECTED COMPETENCIES

Upon completing this Learning Module, the students will be able to:

1. Identify the plasma-arc welding equipment and functions

2. Discuss the principle of operation in plasma-arc welding
3. Describe proper set-up and parameters in plasma-arc cutting

CONTENT/TECHNICAL INFORMATION

Plasma Arc Welding (PAW) is an arc welding process similar to gas tungsten
arc welding (GTAW). The electric arc is formed between an electrode (which is usually
but not always made of sintered tungsten) and the workpiece.

The key difference from GTAW is that in PAW, by positioning the electrode
within the body of the torch, the plasma arc can be separated from the shielding gas
envelope. The plasma is then forced through a fine-bore copper nozzle which constricts
the arc and the plasma exits the orifice at high velocities (approaching the speed of
sound) and a temperature approaching 28,000 °C (50,000 °F) or higher.

Fig. 13.01 – Plasma Arc Welding (PAW). 1. Gas plasma 2. Nozzle protection
3. Shield gas 4. Electrode 5. Nozzle constriction 6. Electric arc
Source: https://en.wikipedia.org/wiki/Plasma_arc_welding

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
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Arc plasma is the temporary state of a gas. The gas gets ionized after passage
of electric current through it and it becomes a conductor of electricity. In ionized state
atoms break into electrons (−) and cations (+) and the system contains a mixture of ions,
electrons and highly excited atoms. The degree of ionization may be between 1% and
greater than 100% i.e.; double and triple degrees of ionization. Such states exist as more
electrons are pulled from their orbits.

The energy of the plasma jet and thus the temperature is dependent upon the
electrical power employed to create arc plasma. A typical value of temperature obtained
in a plasma jet torch may be of the order of 28000 °C (50000 °F) against about 5500
°C (10000 °F) in ordinary electric welding arc. Actually all welding arcs are (partially
ionized) plasmas, but the one in plasma arc welding is a constricted arc plasma.

Just as oxy-fuel torches can be used for either welding or cutting, so too can
plasma torches, which can achieve plasma arc welding or plasma cutting.

Fig. 13.03 – Plasma Arc Welding (PAW) Torch

Source: https://canteach.candu.org/Content%20Library/20053424.pdf

CONCEPT

Plasma arc welding is an arc welding process wherein coalescence is produced

by the heat obtained from a constricted arc setup between a tungsten/alloy tungsten
electrode and the water-cooled (constricting) nozzle (non-transferred arc) or between a
tungsten/alloy tungsten electrode and the job (transferred arc). The process employs
two inert gases, one forms the arc plasma and the second shields the arc plasma. Filler
metal may or may not be added.

HISTORY

The plasma arc welding and cutting process was invented by Robert M. Gage
in 1953 and patented in 1957. The process was unique in that it could achieve precision
cutting and welding on both thin and thick metals. It was also capable of spray coating
hardening metals onto other metals. One example was the spray coating of the turbine
blades of the moon bound Saturn rocket.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
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PRINCIPLE OF OPERATION

Plasma arc welding is an advanced form of TIG welding. In the case of TIG, it
is an open arc shielded by argon or helium whereas plasma used a special torch where
the nozzle is used to constrict the arc and shielding gas is separately supplied by the
torch. The arc is constricted with the help of a water-cooled small diameter nozzle
which squeezes the arc, increases its pressure, temperature and heat intensely and thus
improves arc stability, arc shape and heat transfer characteristics.

Plasma arcs are formed using gas in two forms one is laminar (low pressure and
low flow) and the second is turbulent flow (high pressure and high flow). The used
gases are argon, helium, hydrogen or a mixture of these. In the case of plasma welding
laminar flow (low pressure and low flow of plasma gas) is employed to ensure that the
molten metal is not blown out of the weld zone.

The non-transferred arc (pilot arc) is employed during plasma-welding to

initiate the welding process. The arc is formed between the electrode (-) and the water-
cooled constricting nozzle (+). A non-transferred arc is initiated by using a high-
frequency unit in the circuit. After the initial high-frequency start, the pilot arc (low
current) is formed between the elect by employing a low current. After the main arc is
struck, the nozzle is neutral or in case of welding-mesh using micro plasma, there can
be an option given to have a continuous pilot arc. A transferred arc possesses high
energy density and plasma jet velocity. Depending on the current used and flow of gas,
it can be employed to cut and melt metals.

Microplasma uses current between 0.1 and 10 amps and is used for foils, bellow,
and thin sheets. This is an autogenous process and normally does not use filler wire or
powder. Medium plasma uses current between 10 and 100 amps and is used for higher-
thickness plate welding with filler wire or autogenous up to 6 mm plates and metal
deposition (hardfacing) using specialised torches and powder feeders (PTA) using
metal powders. High-current plasma above 100 amps is used with filler wires welding
at high travel speeds.

Other applications of plasma are plasma-cutting, heating, deposition of diamond

films (Kurihara et al. 1989), material processing, metallurgy (production of metals and
ceramics), plasma-spraying, and underwater cutting.

Fig. 13.03 – Plasma Arc Welding (PAW) Equipment

Source: https://canteach.candu.org/Content%20Library/20053424.pdf

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 4

EQUIPMENT:

The equipment needed in plasma arc welding along with their functions are as follows:

1. Current and gas decay control

It is necessary to close the key hole properly while terminating the weld
in the structure.

2. Fixture
It is required to avoid atmospheric contamination of the molten metal
under bead.

3. Materials
 Steel
 Aluminum
 Other materials

4. High-frequency generator and current limiting resistors

A high-frequency generator and current limiting resistors are used for
arc ignition. The arc-starting system may be separate or built into the system.

5. Plasma Torch
It is either transferred arc or non-transferred arc type. It is hand operated
or mechanized. At present, almost all applications require automated system.
The torch is water-cooled to increase the life of the nozzle and the electrode.
The size and the type of nozzle tip are selected depending upon the metal to be
welded, weld shapes and desired penetration depth.

6. Power Supply
A direct-current power source (generator or rectifier) having drooping
characteristics and open circuit voltage of 70 volts or above is suitable for
plasma arc welding. Rectifiers are generally preferred over DC generators.
Working with helium as an inert gas needs open circuit voltage above 70 volts.
This higher voltage can be obtained by series operation of two power sources;
or the arc can be initiated with argon at normal open-circuit voltage and then
helium can be switched on.

Typical welding parameters for plasma arc welding are as follows:

Current 50 to 350 amps, voltage 27 to 31 volts, gas flow rates 2 to 40
liters/minute (lower range for orifice gas and higher range for outer shielding
gas), direct current electrode negative (DCEN) is normally employed for plasma
arc welding except for the welding of aluminum in which cases water-cooled
electrode is preferable for reverse-polarity welding, i.e. direct-current electrode
positive (DCEP).

7. Shielding gases
Two inert gases or gas mixtures are employed. The orifice gas at lower
pressure and flow rate forms the plasma arc. The pressure of the orifice gas is
intentionally kept low to avoid weld metal turbulence, but this low pressure is
not able to provide proper shielding of the weld pool. To have suitable shielding

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
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protection same or another inert gas is sent through the outer shielding ring of
the torch at comparatively higher flow rates.

Most of the materials can be welded with argon, helium,

argon+hydrogen and argon+helium, as inert gases or gas mixtures. Argon is
commonly used. Helium is preferred where a broad heat input pattern and flatter
cover pass is desired without key-hole mode weld. A mixture of argon and
hydrogen supplies heat energy higher than when only argon is used and thus
permits keyhole mode welds in nickel-base alloys, copper-base alloys and
stainless steels.

For cutting purposes, a mixture of argon and hydrogen (10-30%) or that

of nitrogen may be used. Hydrogen, because of its dissociation into atomic form
and thereafter recombination generates temperatures above those attained by
using argon or helium alone. In addition, hydrogen provides a reducing
atmosphere, which helps in preventing oxidation of the weld and its vicinity.
(Care must be taken, as hydrogen diffusing into the metal can lead to
embrittlement in some metals and steels.)

8. Voltage Control
Voltage control is required in contour welding. In normal key-hole
welding, a variation in arc length up to 1.5 mm does not affect weld bead
penetration or bead shape to any significant extent and thus a voltage control is
not considered essential.

PROCESS DESCRIPTION

Technique of work-piece cleaning and filler-metal addition is similar to that in

TIG welding. Filler metal is added at the leading edge of the weld pool. Filler metal is
not required in making root-pass weld.

TYPE OF JOINTS:

For welding work piece up to 25 mm thick, joints like square butt, J or V are
employed. Plasma welding is used to make both key hole and non-key hole types of
welds.

Making a non-key-hole weld: The process can make non-key-hole welds on

work pieces having thickness 2.4 mm and under.

Making a keyhole welds: An outstanding characteristic of plasma arc welding,

owing to exceptional penetrating power of plasma jet, is its ability to produce keyhole
welds in work piece having thickness from 2.5 mm to 25 mm. A keyhole effect is
achieved through right selection of current, nozzle-orifice diameter and travel speed,
which create a forceful plasma jet to penetrate completely through the work piece.

Plasma jet in no case should expel the molten metal from the joint. The major
advantages of the keyhole technique are the ability to penetrate rapidly through

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
 6

relatively thick root sections and to produces a uniform under bead without mechanical
backing. Also, the ratio of the depth of penetration to the width of the weld is much
higher, resulting narrower weld and heat-affected zone.

As the weld progresses, base metal ahead the keyhole melts, flow around the
same solidifies and forms the weld bead. Key-holing aids deep penetration at faster
speeds and produces high-quality bead. While welding thicker pieces, in laying others
than root run, and using filler metal, the force of plasma jet is reduced by suitably
controlling the amount of orifice gas.

Plasma arc welding is an advancement over the GTAW process. This process
uses a non-consumable tungsten electrode and an arc constricted through a fine-bore
copper nozzle. PAW can be used to join all metals that are weldable with GTAW (i.e.,
most commercial metals and alloys). Difficult-to-weld in metals by PAW include
bronze, cast iron, lead and magnesium. Several basic PAW process variations are
possible by varying the current, plasma gas-flow rate, and the orifice diameter,
including:

 Micro-plasma (< 15 Amperes)

 Melt-in mode (15–100 Amperes)
 Keyhole mode (>100 Amperes)

Plasma arc welding has a greater energy concentration as compared to GTAW.

A deep, narrow penetration is achievable, with a maximum depth of 12 to 18 mm (0.47
to 0.71 in) depending on the material. Greater arc stability allows a much longer arc
length (stand-off), and much greater tolerance to arc-length changes.

PAW requires relatively expensive and complex equipment as compared to

GTAW; proper torch maintenance is critical. Welding procedures tend to be more
complex and less tolerant to variations in fit-up, etc. Operator skill required is slightly
greater than for GTAW. Orifice replacement is necessary.

PROCESS VARIABLES

Gases
At least two separate (and possibly three) flows of gas are used in PAW:

 Plasma gas – flows through the orifice and becomes ionized.

 Shielding gas – flows through the outer nozzle and shields the molten weld from
the atmosphere.
 Back-purge and trailing gas – required for certain materials and applications.
These gases can all be same, or of differing composition.

Key process variables

 Current Type and Polarity DCEN from a CC source is standard.
 AC square-wave is common on aluminum and magnesium.
 Welding current and pulsing - Current can vary from 0.5 A to 1200 A; the
current can be constant or pulsed at frequencies up to 20 kHz.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.
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 Gas-flow rate (This critical variable must be carefully controlled based upon the
current, orifice diameter and shape, gas mixture, and the base material and
thickness.)

OTHER PLASMA ARC PROCESSES

Depending upon the design of the torch (e.g., orifice diameter), electrode
design, gas type and velocities, and the current levels, several variations of the plasma
process are achievable, including:

 Plasma arc cutting (PAC)

 Plasma arc gouging
 Plasma arc surfacing
 Plasma arc spraying

PLASMA ARC CUTTING

When used for cutting, the plasma gas flow is increased so that the deeply
penetrating plasma jet cuts through the material and molten material is removed as
cutting dross. PAC differs from oxy-fuel cutting in that the plasma process operates by
using the arc to melt the metal whereas in the oxy-fuel process, the oxygen oxidizes the
metal and the heat from the exothermic reaction melts the metal.

Unlike oxy-fuel cutting, the PAC process can be applied to cutting metals which
form refractory oxides such as stainless steel, cast iron, aluminum and other non-ferrous
alloys. Since PAC was introduced by Praxair Inc. at the American Welding Society
show in 1954, many process refinements, gas developments, and equipment
improvements have occurred.

REFERENCES

Textbook/s:

Griffin, Roden, Briggs (1978), Welding Processes

On-line:

https://canteach.candu.org/Content%20Library/20053424.pdf

http://www.navybmr.com/study%20material/14250a/14250A_ch8.pdf

Laboratory Manuals:

Department of MET, workshop laboratory manual

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION.