PTA Hardfacing & Cladding

PTA (Plasma Transferred Arc)



Powder Plasma welding system consisting of Controller , power source, colulmn and boom , oscillator, welding positioner, water chiller

Powder Plasma Arc Welding

Plasma Transferred Arc System (PTA) is a high energy, inert gas welding process. Ar is basically used for arc plasma supply, powder transport and molten material shielding. It produces a very high quality deposit offering optimal protection with minimal dilution or deformation of the base material. It is a process that deposits very precise coatings of perfectly controlled alloys on mechanical parts that are subject to intense wear, significantly extending their service life.PTA technology is particularly effective in protection against corrosion, thermal shock and abrasion. A wide range of overlay alloys is available for practically any part. Some alloys are very hard, others are softer with hard abrasion-resistant particles dispersed in a matrix. Certain alloys are made to rebuild a part to a required dimension while others are designed to be a final overlay that protects the work surface.

PTA welding of valve seat	Weld finish of the final complete job
	Click to See Live Demo PTA

Powder Plasma Welding (PPW) is used to

BENEFITS OF PPW:

1. Reduces Cost: Restoring a worn part to "as new" condition generally costs between 20-70% of a brand new replacement part.
2. Prolongs Equipment Life: Service life increases of 3 to 10 times are common with properly overlaid parts.
3. Reduces Downtime: Parts last longer and fewer shutdowns are required.
4. Less Spare Parts Inventory: There is no need to keep numerous spare parts when worn parts can be rebuilt.

PPAW Power Source & Water Chiller / Recirculator	Powder Feeder	Oscillator For Weld Weaving 0-50mm

Welding Positioner with Motorised Tilting	Column & Boom With Process Control Panel	400 Amps. Heavy Duty PPAW Torch

• For Technical Specifications Click Here

TYPES OF WEAR CONDITIONS PPW CAN REDUCE OR ELIMINATE:

Abrasive wear is caused by foreign materials rubbing against a metal part.

Metal-to-metal wear results from non-lubricated friction of metal parts. As metal surfaces slide against each other, the high areas are broken and tiny fragments of metal are torn away.

A blow or a series of blows to a surface resulting in fracture or gradual deterioration. In general, impact resistance
decreases as carbide content is increased. Because abrasion resistance increases with carbide content, a compromise often must be made.

Heat influences wear resistance by:

The deterioration of metal by chemical or electrochemical reaction with its environment.

Wear in which loss of material occurs due to the cutting action of moving particles carried in a fluid stream is termed impingement erosion. At low impingement angles (<15%), hardfacing with large amounts of carbides (hypereutectic alloys), are recommended. At high impingement angles (>80%), large amounts of matrix (hypoeuctectic alloys), are recommended.

Material loss due to very-small-amplitude vibrations at mechanical connections, such as riveted joints. This type of wear is a combination of oxidation and abrasive wear.

Common Materials Used in PPW
PPW is good for substrate materials that are suitable for welding, such as low-carbon steel. The most common PPW materials are nickel alloys and iron/chromium alloys used in wear resistance and high stress abrasion. Common materials for PPW are listed as follows:

POWDER PLASMA WELDING PROCESS (PTA)

Torch Mounted on Oscillator

The PTA welding system can deposit metal alloys on metal surfaces at rates of up to 20 lb/h . The system can be fitted with automated manipulators to handle different parts, even those with complex shapes and narrow tolerances

The PTA system works with different metal powders as filler material, such as chrome carbide, tungsten carbide, and nickel- and cobalt-based powders. Future development could also see the use of ceramic-based powders. Using these hard-wearing materials can improve the durability of the weld.

When used to deposit powder metal alloys on a substrate, the PTA system has a dilution level of 3 to 7%. Compare this to submerged arc systems, which can dilute the base metal by as much as 40%. Combined with a narrow heat-affected zone, the PTA system's low dilution rate prevents undesired substrate changes and can enhance the alloy's wear performance in applications for manufacturing wear components. It also results in a smooth surface finish for easier and quicker finishing and machining.

THE EFFECT OF DILUTION:

The welding heats required for proper application of PPW materials are not necessarily the same as those required for structural welding. Instead of producing an admixture of two compatible metals, as in structural welding, PPW provides a bead or a surface deposit of alloyed metal located to resist impact or abrading action. The process requires only sufficient application heat to obtain a sound bond with the parent metal. Admixtures of the two metals are minimized.

Using too much heat during hardface welding will dilute the hardface alloys with the base metal, thereby reducing effective wear resistant properties of the material.

Excessive heats will vaporize the alloys and will cause oxidation. Overly heated weld puddles can further result in
such fluid condition of the alloys that they create a thinner deposit than may be intended. Insufficient welding heat, on the other hand, will cause insecure bonds with the base metal and can possibly result in spalling. A cold weld deposit, especially when applied to chilling metal, will often cool rapidly enough to create shrinkage, more commonly called "cold checks." Such fractures can also result in eventual spalling of metal.

APPLICATIONS

In a competition with laser surfacing the PTA technology offers much more high productivity, comparable high quality of deposits and significantly lower costs.

Typical application areas of the PTA technology are extruding machine screws, valves, valve seats of internal combustion engines (motorcar, marine, locomotive etc.), accessories for ships, petroleum chemistry and power generation, cutting tools (milling cutters, broaches, knifes) ,Equipment for mining, crushing, rolling, road building and tunneling, Process equipment in ceramics and cement production,Molds and forging dies, Pulp and paper industry equipment, Agricultural equipment, parts for nuclear plants, parts for chemical plants

SUMMARY

Motorcycle Exhaust Valve	Gate Plug	Valve Seat

Valve Disc and Stem		Mechanical Seal

P.T.A. DEPOSITS SHOW THE FOLLOWING CHARACTERISTICS:

Technical Specifications of PTA System

Welding Turntable

Welding Positioners

* Higher Models Available - Specifications given on request

Oscillator

X-Y Slide

Controller

Powder Feeder

Welding Lathe

Column & Boom

Plasma Torch

Water Recirculator Cum Chiller

* Specifications subject to change for further improvement..