PAW NEW

Plasma ARC Welding
(PAW)
Content
O Introduction
O How Plasma Welding works?
O Equipment
O Welding Modes in PAW
O Difference between PAW
and TIG
O Control System
O Advantages
O Disadvantages
O Applications
Introduction
 Arc welding process
that produces
coalescence of metals
by heating them with
a constricted arc
between an electrode
and the work piece
(transferred arc) or
between the electrode
and the water-cooled
constricting nozzle
(non transferred arc) .
 Plasma: A gaseous
mixture of positive
ions, electrons and
neutral gas molecules.
PAW Welding
How Plasma Welding
Plasma:
Works
O Gas which is heated to an extremely high
temperature and ionized so that it becomes
electrically conductive.
O PAW process uses this plasma to transfer an electric
arc to the work piece.
O The metal to be welded is melted by the intense
heat of the arc and fuses together.
Objective of PAW:
O To increase the energy level of the arc plasma in a
controlled manner.
O This is achieved by providing a gas nozzle around a
tungsten electrode operating on DCEN.
2 Variants of PAW:
Transferred arc mode:
O Arc is struck between the electrode(-) and the work piece(+)
O Used for high speed welding and
O Used to weld Ceramics, steels, Aluminum alloys, Copper
alloys, Titanium alloys, Nickel alloys.
Non-transferred mode:
O Arc is struck between the electrode(-) and the nozzle(+), thus
eliminating the necessity to have the work as a part of the
electrical system.
O Arc process produces plasma of relatively low energy density.
O Since the work piece in non-transferred plasma arc welding is
not a part of electric circuit, the plasma arc torch may move
from one work piece to other without extinguishing the arc.
Fig. Arc in Plasma Arc Welding
Equipment
Power Supply
O A DC power source (generator or rectifier) having
drooping characteristics and open circuit voltage of
70 volts or above is suitable for PAW.
O Rectifiers are generally preferred over DC
generators.
O Working with He as an inert gas needs open circuit
voltage above 70 volts. This 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.
High frequency generator and current limiting
resistors
O Used for arc ignition.
Plasma Torch
O Either transferred arc or non transferred arc typed
Shielding gases
O Shields the molten weld from the atmosphere.
O Two inert gases or gas mixtures are employed.
O Argon(commonly used), Helium, Argon+Hydrogen
and Argon+Helium, as inert gases or gas mixtures.
O Helium is preferred where a broad heat input
pattern and flatter cover pass is desired.
O A mixture of argon and hydrogen supplies heat
energy higher than when only argon is used and
thus permits higher arc alloys and stainless steels.
O For cutting purposes a mixture of argon and
hydrogen (10-30%) or that of nitrogen may be used.
O Hydrogen, because of its dissociation into atomic
form and thereafter recombination generates
temperatures above those attained by using argon
or helium alone.
Welding Parameters:
O Current 50 to 350 Amps,
O Voltage 27 to 31 Volts,
O Gas flow rates 2 to 40 liters/min. (lower range for
orifice gas and higher range for outer shielding gas),
O DCSP is normally employed except for the welding of
Al in which cases water cooled copper anode and
DCSP are preferred.
O Temp of Jet 50000°F (28000°C)
Current and gas decay control

O To close the key hole properly while terminating the
weld in the structure.
Fixture
O To avoid atmospheric contamination of the molten
metal under bead.
Modes in paw
Micro-plasma welding
O Welding Current from 0.1A to 15A.
O Arc Length is varied up to 20mm
O Used for welding thin sheets (0.1mm thick), and wire
and mesh sections.
Medium-plasma welding
O Welding current from 15A to 100A.
Keyhole welding
O Welding Current above 100A, where the plasma arc
penetrates the wall thickness.
O Widely used for high-quality joints in aircraft/space,
chemical industries to weld thicker material (up to
10mm of stainless steel) in a single pass.
 Sunken Bead Undercut too much
penetration
 Welding current is too high
 Travel Speed is too low
 Bead too small, Irregular Little
Penetration
 Welding Current and Plasma Gas Flow
is too low
 Travel is too fast
 Undercut and Irregular Edges
 Plasma Gas Flow is too high
 Proper Size Bead, Even Ripple and

Good Penetration
 Correct Current, Even torch movement,
Proper Arc Voltage and Plasma Gas
Quality and Common
Flow
Faults
Difference between PAW and TIG
Plasma Arc Welding Tungsten Inert Gas Welding
 Two gases are used, One for Plasma  Only one gas used, which forms
Gas and other for Shielding Gas. plasma as well as shields the arc
and molten weld pool.
 Uses Constricted Arc.  Uses Non-Constricted Arc.
 Temp. of about 11000°C is achieved.  Temp. of about 4000°C is

achieved.
 Deep Penetration is achieved.  Penetration obtained is not so
deeper.
 No Filler Material is required.  More Filler Material is required.
 Fast Metal Deposition Rate.  Metal Deposition Rate is not so

faster.
 Inert Gas Consumption is very high.  Inert Gas Consumption is very
low.
 Costly welding equipment.  Less costly welding equipment.
 Cutting of Hard and Brittle Material is  Cutting of Hard and Brittle

possible. Material is not possible.
Control System
Advantages
O Permits faster metal deposition rate and high arc
travel speed as compared to TIG
O Uniform penetration with high welding rate is possible
O Stability of arc and Excellent weld quality
O Can produce radiographic quality weld at high speed
O Can weld steel pieces up to about half inch thick,
square butt joint
O Useful for semi automatic and automatic processes.
O Process is very fast and clean
O Requires less operator skill due to good tolerance of
arc to misalignments;
O High penetrating capability (keyhole effect);
Disadvantages
O Special protection is required as Infrared and UV
Radiations is produced
O Consumption of Inert Gas is high
O Needs high power electrical equipment.
O Gives out ultraviolet and infrared radiation.
O Operation produces a high noise of the order of
100dB.
O Expensive equipment;
O Can weld only upto 25mm thickness.
O High distortions and wide welds as a result of high
heat input (in transferred arc process).
O More chances of Electrical hazards.
applications
 Aerospace Industries
 Cryogenics
 Foodstuff and
Chemical Industries
 Machine and Plant
Construction
 Automobiles and
Railways
 Ship Construction
 Tank Equipment and
Pipeline Construction
etc.
Base Metal weldable by Plasma Arc
Process:
Easily Weldable:
O Al, Cu-base alloys (Cu, Cu-Ni), Magnesium, Ni-
base alloys (Inconel, Nickel, Monel), Precious
Metals, Steels (Low Carbon Steel, Low Alloy
Steel, Stainless Steel, Tool Steels), Titanium
(upto 8mm thick) etc...
Acceptable but weldable with care:
O Cast, Malleable, Nodular Iron, Wrought Iron,
Lead, Tungsten etc...
Possible but not Popular:
O Bronzes, Brass, Nickel Silver, Lead, Zinc etc...
P Protected electrode, offers long times before electrode
maintenance (usually one 8 Hr Shift)
L Low amperage welding capability (as low as 0.05 amp)
A Arc consistency and gentle arc starting produce

consistent welds, time after time
S Stable arc in arc starting and low amperage welding
M Minimal high frequency noise issues, HF only in pilot

arc start, not for each weld
A Arc energy density reaches 3 times that of GTAW.

Higher weld speeds possible
W Weld times as short as 5 millisec (.005 sec)
E Energy density reduces heat affected zone, improves

weld quality
L Length of arc benefit due to arc shape and even heat
distribution
D Diameter of arc chosen via nozzle orifice

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Plasma ARC Welding

Current and gas decay control

 Proper Size Bead, Even Ripple and

 Temp. of about 11000°C is achieved.  Temp. of about 4000°C is

 Fast Metal Deposition Rate.  Metal Deposition Rate is not so

 Cutting of Hard and Brittle Material is  Cutting of Hard and Brittle

A Arc consistency and gentle arc starting produce

M Minimal high frequency noise issues, HF only in pilot

A Arc energy density reaches 3 times that of GTAW.

W Weld times as short as 5 millisec (.005 sec)

E Energy density reduces heat affected zone, improves

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