Plasma Cutting Machines
Plasma Transferred Arc Welding (PTA)
Welding Automation
Plasma Welding
Micro Plasma Welding Machines
Micro Tig Welding Machines
Welding Inverters
Welding Data
Welder Training & Certification

 
 
Plasma Welding

Automated Plasma Welding for Highest Quality and Maximum productivity.


MP 200
Plasma Weld
Plasma Weld
MP200 with Lathe
 

Perform High Class Welding With High Tech Plasma Welding Systems.

Advantages of Plasma Welding

  1. Less sensitivity to changes in Arc length.
  2. Recessed electrode reduces the possibility of tungsten inclusions in the weld and can substantially increase the period between electrode dressings resulting in increased life.
  3. Weld in a single pass up to 6 mm plates in square butt position and 10 mm plates in only  two passes.
  4. 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.
  5. Reduced weld time results in less embrittlement by carbides and complex intermetallic compounds for stainless steel and super alloys.
  6. Equalization of distortion stresses results in less residual stress.
  7. 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


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. 

We can supply custom built Plasma welding systems with automation and accessories
to suit the requirements of your job
Standard specifications of automation system and accessories


Welding Automation
01. Welding Gun 02. Oscillator ( weld weaver )
03. Cold wire feeders 04. Seam trackers
05. Torch Height Controller 06. Cameras and video displays
07. Manual slides ( manual and motorized ) 08. Welding turntables
09. Welding positioners 10. Welding Turning Rolls
11. Welding lathes 12. Column and boom ( manipulators )
Hardfacing
01. FCAW 02. Hardbanding
03. PTA 04. SAW / ESW Strip cladding
05. SAW hardfacing    


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.

ARCRAFT PW 200 and PW 400 Plasma welding machines operational capabilities

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.




Welded Coupon of 5mm SS Plate completed in one single pass using Key hole Plasma process

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.

This has several advantages which can be exploited deep penetration and high welding speeds compared with the TIG arc, it can penetrate plate thicknesses up to 10 mm, but when welding using a single pass technique, it is more usual to limit the thickness to 6mm.

For thickness up to 15mm, a V- joint preparation is used with a 6mm root face. As the welding parameters, plasma gas flow rate and filler wire addition (into the keyhole) must be carefully balanced to maintain the keyhole and the weld pool stability, this technique is only suitable for mechanized welding when pipe welding, the slope out of current and plasma gas flow must be carefully controlled to close the keyhole without leaving a hole.

Electrode
The electrode used for the plasma process is tungsten and the plasma nozzle is copper. The electrode tip diameter is not as critical as for TIG and should be maintained at around 30-60degrees 

Nozzle
The plasma nozzle bore diameter is critical and too small a bore diameter for the current level and plasma gas flow rate will lead to excessive nozzle erosion or even melting. Large bore diameter should be carefully used for the operating current level .Because too large a bore diameter, may give problems with arc stability and maintaining a keyhole.

Plasma and Shielding gases
The normal combination of gases is argon for the plasma gas, with argon plus 2 to 5% hydrogen for the shielding gas only for austenitic stainless steels. Helium can be used for plasma gas but because it is hotter this reduces the current rating of the nozzle. Helium's lower mass can also make the keyhole mode more difficult.

Joint preparation for different welding processes



Welding speed (cm/min.)

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

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.

 

 


 

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.

Unique Features of ARCRAFT Plasma Welding Machine Model PW 200 and PW 400
1. Customization of technical features possible.
2. Programmable Current and Gas Down Slope available for automatic closing of key hole during mechanized welding.

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.

 

Plasma Cutting Machines

For precision cutting of Stainless steel, Aluminium and all other Ferrous and Non-ferrous metals.
Stainless Steel cutting upto 150 mm thick plates.

PTA Hardfacing & Cladding

(PTA) for Hardfacing / Cladding / Reclamation & Protection of Mechanical parts.

Welding Automation

Increase Productivity and    Capacity
Repeatable high quality    welds
Enhance Quality
Custom made solutions


Plasma Welding

Less sensitivity to changes in  
 Arc length.

Micro Plasma Welding Machines

 Precision welding of     minature    
    parts
 Controlled Arc at low currents
 Automated welding at low
    currents.
 With built-in Pilot arcing     system.

Micro Tig Welding Machines

 Precision welding of     minature parts
 Ideal for smaller repair or
    Assembly work.
 Built-in high frequency     ignition.

Welding Inverters

Light weight & compact : 80% less weight compared to conventional machines.
 


Manufacturers of
Plasma Powder welding machines (PTA), Hardbanding machines, Column and Boom, Welding positioners and Rotators, Plasma torches & consumables - Welding Inverters, Plasma Cutting Machines, Micro-Tig Welding Machines, Micro Plasma Welding Machines, AC Welding Machines, Mig welding Machines, Shape Cutting Machines, Special Purpose Machines for hardfacing and cladding.


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