Plasma-welding

FRONIUS International GmbH

Sparte Schweisstechnik/ Welding Technology
Tech. Cenetre
Buxbaumstraße 2
A-4600 Wels
Austria

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© Fronius 01/2004
Overview of welding process

Protective gas welding

(SG)

Wolfram protective gas welding Metal protective gas welding

(WSG) (MSG)

Wolfram Wolfram Plasma Metal Metal aktive gas

inert gas plasma metal inert gas weling
welding welding gas welding
(WIG) (WP) welding
(MSGP) (MIG) (MAG)

Plasma Plasma Plasma

beam arc beam Mixed CO2
welding welding plasma gas welding
arc welding
(not (transmitting (MAGM) (MAGC)
transmitting arc)
welding
arc)
(WPS) (WPL) (WPSL)

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

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Difference between WIG- and plasma arc
Transmitting
arc

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 shunting
possible 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 mm
up 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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 Einflussgrößen at plasma welding

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

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Selection of plasma gas (pilot gas)

Inert gas Material (application area) / effect

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

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Selection of inert gas
Inert gas Material (application area) / effect

Argon => all metallic materials:

=> standard gas
=> good ignition characteristics
=> good stability of arc
Ar/H2-mixtures => 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/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

brazing

brazing brazing brazing brazing brazing

through through through through through
liquid gas electrical steel electrical
gas current
discharge

Arc-brazing

Metal Wolfram
inert gas inert gas
brazing brazing
(MSGL) (WSGL)

Metal Metal Wolfram Wolfram

inert gas active gas inert gas plasma
brazing brazing brazing brazing
(MIG- (MAG- (WIG- (WP-
brazing) brazing) brazing) 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 welding
with 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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© Fronius 01/2004
Plasma welding
with 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 welding
Continuation (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 sufficient
experimental 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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Request catalogue: plasma-welding

Further measures:

Use original parts for the plasma torch

Assembly and attitude of the plasma torch make after

manufacturer discription

The welding parameters must be reproducible, e.g. by the

digital selection and use of jobs

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Request catalogue: plasma-welding

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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Plasma welding power sources:

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Plasma welding power sources:

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Plasma welding power sources:

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Plasma welding power sources:

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