plasma welding englisch

© Fronius 01/2004

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FRONIUS International GmbHSparte Schweisstechnik/ Welding TechnologyTech. CenetreBuxbaumstraße 2A-4600 WelsAustria

Plasma-welding

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Overview of welding process

Protective gas welding

(SG)

Wolfram protective gas welding

(WSG)

Metal protective gas welding

(MSG)

Wolfram

inert gas

welding

(WIG)

Wolfram

plasma

welding

(WP)

Plasma

beam

welding

(not

transmitting

arc)

(WPS)

Plasma

arc

welding

(transmitting

arc)

(WPL)

Plasma

beam

plasma

arc

welding

(WPSL)

Plasma

metal

gas

welding

(MSGP)

Metal

inert gas

welding

(MIG)

Metal aktive gas

weling

(MAG)

Mixed

gas

welding

(MAGM)

CO2

welding

(MAGC)

Definition and short marks according to DIN 1910-4 (excerpt)

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Difference between WIG- and plasma arc

Transmittingarc

� Plasma-welding in welding technology is an arc, constricted by a nozzle (plasma nozzle), which serves as heat source.

� The plasma beam consists of an accelerated and ionized gas jet.

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Difference between WIG- and plasma arc� Higher welding speed according to material and material thickness

� Excellent welding seam quality

� Excellent seam appearance

� Smaller WEZ, because of that less part deformation

� One-sided welding without root against-welding

� Through using additional materials a crack shuntingpossible and a Nahtüberhöhung is definable

� Reduction of number of layers at large wall thickness in connection with hot wire

� High electrode endurance through use of a plasma-, pilot- or auxiliary arc

� Welding in all positions with pulsed current and to current synchronized plasma gas

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Principle: plasma-welding / plasma-brazing

Source: Brune, E.: Schweiß-und Schneidtechnik (PanGas, Luzern)

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Principle: plasma-welding

Plasma-welding with hot wire supply

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Variants of plasma-welding

� Micro-welding: sheet thickness:from 0,01 mmup to 25 amp.

� Plasma- or soft-plasma- sheet thickness:welding: from 0,6 mm to 3,0 mm

> 25 amp. up to about 500 A

� Plasma-tapping hole- sheet thickness:welding: from 3,0 mm to 10,0mm

> 60 Amp. up to about 500A

� Plasma-brazing: brazing galvanized sheet

Information from DVS-leaflet 2707

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(Soft-) plasma-welding

� The auxiliary arc (HILIBO) guarantees a safe ignition of the main arc

� Partially higher welding speed compared with WIG

� Immersion of the wolfram-electrode into the melting bath is

not possible

� Higher availability and higher wolfram-electrode

endurance (number of ignitions)

� Application areas:� pipeline- and appliance construction� and melding units

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Plasma-tapping hole-welding

� The auxiliary arc guatantees a safe ignition of the main arc

� Material thickness up to 10 mm

without complex seam

preparation in one layer weldable

� High welding seam quality with

excellent appearance

� The high power density at the workpiece causes small

melting baths and thin heat-affected zones (WEZ)

� Application areas:pipeline- and appliance construction, pressure vessel

construction,...

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Plasma-tapping hole-welding

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� Welding speed: � constant speed

is neccessary

� Plasma gas rate: � constant + accurate adjustable

� Component construction and- tolerances

� Seam preparation

� Plasma jet diameter

� Torch clearance

� Inert gas:Ar, Ar/CO2, Ar/He, Ar/H2

Einflussgrößen at plasma welding

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Selection of plasma gas (pilot gas)

=> all metallic materials:=> standard gas => good ignition characteristics => good stability of arc

Argon

Material (application area) / effectInert gas

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Selection of inert gas

=> ordinary and austenitic steel

=> not right for gas-sensitive (Ti, Zr)

or ferritic materials (f. ex.: duplex)also aluminium- and copper materials

=> improved protection of oxydation

=> (increase of welding speed)

Ar/H2-mixtures

=> all metallic materials:

=> standard gas => good ignition characteristics

=> good stability of arc

Argon

Material (application area) / effectInert gas

Ar/He-mixtures => all materials:

=> increase of welding speed => worse ignition characteristics

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Torch setting angle

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Arrangement of the process for arc brazing

Arc-brazing

brazing

brazing

through

liquid

brazing

through

gas

brazing

through

electrical

gas

discharge

brazing

through

steel

brazing

through

electrical

current

Metal

inert gas

brazing

(MSGL)

Wolfram

inert gas

brazing

(WSGL)

Metal

inert gas

brazing

(MIG-

brazing)

Metal

active gas

brazing

(MAG-

brazing)

Wolfram

inert gas

brazing

(WIG-

brazing)

Wolfram

plasma

brazing

(WP-

brazing)

Overview from DVS-leaflet 948

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Plasma brazing

� The pilot arc guarantees a safe ignition of the main arc

� Seperated energy- and wire supply (cold- or hot wire)

� Similary TIG-brazing, but higher energy thickness through arc necking

� Solid arc

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Plasma-brazing

� Perfect, spatterfree seams with excellent strength characteristics

� Less spatter than at MIG-brazing through cold wire supply

� Higher brazing speed with hot wire supply

� Application area:brazing of galvanized sheet

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Plasma-brazing

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Summary: plasma-brazing

� Welding process for the high-quality connecting of galvanized sheet

� Reduced corrosion

� For fully automated applications

� Flexible method because of excellent welding technology, also usable for robot employment

� Numerous references are present already

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Plasma-welding units: modular design

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Plasma power source (example)

Fronius Plasma Module FPM

Employment with (nearly) every WIG power source

� Pilot current: preset according to torch type(8A/20A)

� Digital display: pilot arc current

� HF-ignition for pilot arc

� Plasma gas: continuously adjustable(0,6-10 l/min)

� Digitale display: plasma gas rate

� Selection internal / external control(0-10 volt) for plasma gas

� Gas test button

� Start button pilot arc

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Plasma weldingwith a robot with cold wire equipment

1. Plasma module

2. Power source

3. Fieldbus interface

4. Cooling unit

5. Carriage

6. Hose pack

7. Plasma torch

8. Hose pack

9. Wire feed unit

10. Cold wire supply

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Plasma weldingwith a robot with cold wire equipment

1. Plasma module

2. Power source

3. Fieldbus interface

4. Cooling unit

5. Carriage

6. Hose pack

7. Plasma torch

8. Remote control cable

9. Roboter wire feeder

10. Wire coil supply

11. Wire feed hose

12. Torch cold wire supply

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Plasma torch

PTW 1500

� Plasma robot torch

� ED100% at 150 A – pole

50 A + pole

� Wire supply (option),also with cold wire drive

� Application areas:C-steel, CrNi, Ni and Ni-alloy,titanium, Al and Al-alloy,...

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Plasma torch PMW 350

� Plasma machine torch

� ED100% at 350A – Pole

100A + Pole

� Wire supply (option)

� Water cooled protection gas nozzle or extensive protection-/dragging gas nozzle (option)

� Application areas:C-steel, CrNi, NiBas, titanium, Al, Al-alloy,...

� Up to 10mm material thickness

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Documentation: plasma welding

� Welding- and process parameters are available in the plasma welding unit

� They can be used for the welding data documentation

� They can be forwardet to the upstream control, e.g.: FPA 9000, for processing or storing

� Customers demand more documentation

� Numerous references

are present already

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Request catalogue: plasma welding

Plasma welding offers lots of advantages, but our experience has shown that we have to pay attention to some details (conditions / measures), specially at high number of pieces:

Conditions:

� The welding-technical responsible persons should have a welding-technical specialized knowledge

� The manufacturing employees should have a good education and need a specialized introduction

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Request catalogue: plasma weldingContinuation (conditions):

� The manufacturing-technical feasibility should be cleared up at the construction phase under consideration of the manufacturing tolerance

� There should be a careful production planning with a sufficientexperimental phase

� Including of manufacturing quantity and –surroundings,

e.g.:=> Installation place (adherence to the cycle

times) => Ambient temperatures=> Material pretreatment and delivery

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Request catalogue: plasma-welding

Measures for the trouble-free operation:

� The plasma welding power source has to be designed for the demands: configuration

� The inert gas supply must tie up with the demands:

=> exact adjustment possibility and readability of the inert gas quantity

=> diffusion-close inert gas lines

(e.g.: metal, rubber,...)

� The cooling for the plasma torch must be laid out for 100 % ED (consider site conditions!)

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Further measures:

� Use original parts for the plasma torch

� Assembly and attitude of the plasma torch make aftermanufacturer discription

� The welding parameters must be reproducible, e.g. by thedigital selection and use of jobs

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Further measures:

� The welding appliance at automated welding should correspond to a high quality standard: consulation

� The chuck jaws should be corresponding substantial or separate cooled, particulary with series production or multi layer operation

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