Plasma arc welding is a more focused and automated process than gas tungsten arc welding, using a narrow copper orifice to create a plasma arc that can reach high temperatures and speeds. It requires at least two types of gas and can be varied based on key components. However, it is more expensive and complex, requires routine maintenance and orifice replacement, and requires a higher level of operator skill.
Plasma arc welding (PAW) is a process used instead of gas tungsten arc welding (GTAW). It can be used to weld any metal that can be welded using gas tungsten arc welding, which includes nearly all commercially used alloys and metals. Plasma arc welding is considered an improvement over the GTAW process because the arc is more focused.
The electrode of the plasma arc welder is positioned inside the torch body. This allows the plasma arc and the shielding gas to be separated, which distinguishes plasma arc welding from gas tungsten arc welding. Plasma is forced through a copper orifice at very high temperatures and speeds. The plasma arc reaches nearly 36,032 degrees Fahrenheit (about 20,000 degrees Celsius) and reaches speeds close to that of sound.
The plasma arc is focused by the narrow constriction of the copper orifice. This increased focus gives the process greater arc stability and energy concentration than GTAW. Additionally, the focused arc used in this method allows the process to be used in automated equipment, thus eliminating the need to endanger human workers for hazardous welding operations.
The plasma arc welding process can also be varied based on key components: the electrical current used to create the arc, the plasma gas flow rate, and the diameter of the copper orifice. By modifying any of these components, it is possible to obtain different plasma arc welding results and methods. The three most common variations of the plasma arc welding process are microplasma, melt-in mode and keyhole mode.
Plasma arc welding requires at least two types of gas to flow. These types of gases are plasma gas and shield gas. The actual welding process uses plasma gas and the shielding gas acts as a flux, shielding the weld from the outside atmosphere. A third type of gas, called trailing gas or back-purge, may also be needed when welding certain metals.
While plasma arc welding is an improvement over gas tungsten arc welding, there are some drawbacks that limit its use. This process is very expensive and complex compared to the gas tungsten arc welding process. Plasma arc welding requires routine torch maintenance and orifice replacement. The equipment used for plasma arc welding also requires a higher level of operator skill than gas tungsten arc welding, and this process is less forgiving in terms of fit variations and tolerances.
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