Plasma Welding
Perform High Class Welding With High Tech Plasma Welding Systems.
| 3 PROCESSES IN ONE MACHINE |
| Plasma Welding |
TIG DC Welding |
MMAW (STICK) DC Welding |
Weld Unalloyed , Low Alloy and High Alloy Steels , Nickle,Copper , Titanium , Zircon andTheir Alloys and Special Materials |
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Weld Unalloyed , Low Alloy and High Alloy Steels , Nickle, Copper, Titanium , Zircon and Their Alloys and Special Materials |
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Coated Electrodes , Rutile and Basic, Non Alloy and High Alloy Steels, Nickel Based and Copper Alloys. |
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Advantages of Plasma Welding
Less sensitivity to changes in Arc length.
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Recessed electrode reduces the possibility of tungsten inclusions in the weld and can substantially increase the period between electrode dressings resulting in increased life.
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Weld in a single pass up to 6 mm plates in square butt position and 10 mm plates in only two passes.
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Keyhole mode of welding gives smaller heat affected zone resulting in reduced strength loss at the joint for heat treated metals, promotes less grain growth which gives better ductility.
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Reduced weld time results in less embrittlement by carbides and complex intermetallic compounds for stainless steel and super alloys.
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Equalization of distortion stresses results in less residual stress.
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Less filler metal required in keyhole mode significantly reduces porosity.
Model Specifications
| MODEL SPECIFICATIONS |
PW 200 |
PW 400 |
Input Supply
|
415V +/-10% |
415V +/-10% |
| Phase/ Freq. |
3/50-60Hz |
3/50-60Hz |
| Max Power |
8.15KW/11HP |
16.3KW/22HP |
| Input KVA @ 60% |
8.9 |
17.8 |
| Input KVA @100% |
6.85 |
13.7 |
| Current Range (Amp) |
5-200 |
5-400 |
| Current @ 60% |
200 |
400 |
| Current @ 100% |
160 |
308 |
| OCV (Volts) |
75-85 |
75-85 |
| Pre Flow |
1-5 Sec |
1-5 Sec |
| Post Flow |
1-5 Sec |
1-5 Sec |
| Up Slope |
1-5 Sec |
1-5 Sec |
| Down Slope |
1-5 Sec |
1-5 Sec |
| Plasma Gas Down Slope |
1-5 Sec |
1-5 Sec |
| Pulse Frequency (Hz) |
1-100 |
1-100 |
| Pulse Time |
10-90% |
10-90% |
| Pre Settable Current |
Yes |
Yes |
| Class of Insulation |
H |
H |
| Pilot Arc Current (Amp) |
5 |
5 |
| Power Source |
Cooling Air |
cooled Air cooled |
| Torch Cooling |
Water cooled |
Water cooled |
| Dimensions W x L x H |
700 x 685 x 920 (mm) |
700 x 685 x 920 (mm) |
| Weight in Kgs. |
125 |
145 |
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What is Plasma Welding ?
 Plasma arc welding (PAW) is a advanced version of the tungsten inert gas (TIG) welding process. TIG welding has a free-burning arc, which is unstable and tends to wander in the low current range. With increase in current, the arc power increases and the arc diameter also increases.
This leads to a lack of concentrated power in the work-piece, which results in a bigger seam and a larger heat-affected zone. Unlike TIG-welding torches, PAW uses a constricting nozzel and employs two separate gas flows, which give rise to a concentrated plasma arc having a narrow columnar shape.
The plasma column is now stabilized along the axis of the electrode and is more intense than the TIG-welding arc. The column temperature is 10,000-24,000 K compared to 8,000-18,000 K in case of TIG-welding.
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ARCRAFT PW 200 and PW 400 Plasma welding machines operational capabilities
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Arc Modes in Plasma Welding |
1. Manual plasma-arc welding is usually adapted to non key hole fusion type welding.
2. Mechanized plasma-arc welding is required for high current plasma-arc applications such as making key hole-mode welds or high current filler passes.
Metals welded by these processes: Weld unalloyed, low alloy and high
alloy steels, nickle, copper, titanium, zircon and their alloys and special
materials.
TOP... Welded Coupon of
5mm SS Plate completed in one single pass using Key hole Plasma process
TOP... The Plasma-keyhole welding process
The Plasma-keyhole method is a welding process where the gas flow is restricted through a reduction of the gas orifice. This increases the gas velocity and the arc temperature. The plasma arc blows a hole through the joint or the plate. Behind the hole the molten metal flows together filling the hole, due to the gravity forces, surface tension and the gas pressure from the shielding gas.
The advantage of the Plasma-keyhole technique is the ability to weld simple I-butt joints in one single run up to a plate thickness of 8 mm. This will greatly improve welding efficiency. An other advantage is the limited distortion obtained with the process due to the even distribution of heat through the plate thickness. TOP... Joint preparation for different welding processes
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Welding speed (cm/min.)
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Example of productivity gain with carbon steel (5mm):
- MMAW: preparation + 2 passes at 15 to 20 cm/min +slag removal + grinding.
- Manual TIG: preparation + 2 passes at 10cm/min.
- Key hole plasma: 1 pass at 40 cm/min.
| Thickness (mm) |
Plasma cm/min |
3 |
50 |
4 |
35-40 |
6 |
25-30 |
8 |
15-20 |
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Approximate heat input for different welding process
Maximum plate thickness that can be welded in one pass without
preparation using plasma process :
Carbon steel and stainless steel, austenitic up to 8 mm, titanium
up to 10 mm.
TOP... Cost of Welding with TIG/Plasma
 In thicknesses from 2.5 to 10 mm, plasma arc welding (downhand or horizontal- vertical) achieves significant productivity improvements through:
- reduced preparation time (no welding preparations, square edge butt Without gap),
- reduced welding time (single pass),
- reduced finishing and clean-up times,
- elimination of rework due to lack of defects.
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Unique Features of ARCRAFT Plasma Welding Machine Model PW 200 and PW 400
1. Designed and manufactured Indigenously for the first time in India.
2. Customization of technical features possible.
3. Programmable Current and Gas Down Slope available for automatic closing of key hole during mechanized welding.
4. Indigenously made spares readily available at reasonable price.
5. Service available all over India.
6. Plasma Gun guaranteed for 6 months and power source guaranteed for 1 year against any manufacturing defect
TOP... User Industries
Aerospace and Space Industries, Cryogenics, Foodstuff and Chemical Industries, Machine and Plant Construction, Automobile,
Railway, Ship Construction, Tank, Equipment and Pipeline Construction etc.
* Technical information given in this brochure are to the best of our knowledge, but we do not undertake any responsibility for the use there of.
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