PRACTICAL-REPORT

Plasma - Welding
TABLE OF CONTENTS

Principle of plasma-welding...................................................................................................... 1

Advantages of plasma-welding................................................................................................. 2

Performance characteristics of the plasma-process using filler wire...................................... 3

Seam preparations.................................................................................................................... 3

Characteristics of the weld pool ...............................................................................................4

Behaviour of the weld pool ....................................................................................................... 4

Factors in maintaining the stability of the weld pool................................................................ 5

Plasma welding in industry ....................................................................................................... 6

Criteria for using plasma-keyhole-welding............................................................................... 7

Plasma welding with pulsed plasma gas ................................................................................. 8

Technical Data PlasmaTig 450 – Plasma-Welding Power Source ........................................... 9

Technical Data System-Contoller FPA 2003 Plasma ............................................................. 11

Technical Data System-Contoller FPA 9000 Plasma ............................................................. 13

PRINCIPLE OF PLASMA-WELDING
Definition

PLASMA ARC WELDING is basically an extension of the gas tungsten arc welding (GTAW or TIG) process.
However, it has a much higher arc energy density and higher plasma gas velocity by virtue of the plasma
being forced through a constricting nozzle.

The plasma process is generally used for welding and cladding. It can weld the most common metals up to a
thickness of approx.10 mm. Using suitable torches it can even be used on aluminium, up to a plate thickness
of approximately 5 mm.

The main applications for plasma welding are in the construction of containers and the manufacture of pipes.
Micro-plasma welding is used in technology for household appliances, electronics, aviation and space
technology, medical technology and apparatus and instrumentation engineering.

Principle of plasma-welding

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ADVANTAGES OF PLASMA-WELDING

• Mechanical constriction of the arc by a water-cooled nozzle enables welding of greater thickness in square butt
preparation (3 mm up to10 mm) with a lower heat affected zone (keyhole weld)

• Increased welding speed from 50 mm/min to 500 mm/min, depending on materials and the material thickness

• Reduction in the number of weld layers on greater thickness when combined with the hot wire process

• High electrode service-life due to the use of a pilot arc

• Excellent weld quality

• Minimal distortion

• Single sided welding with good root penetration

• Welding in all positions with synchronisation of pulsed current and plasma gas

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PERFORMANCE CHARACTERISTICS
OF PLASMA-PROCESS USING FILLER WIRE

• Butt welding of materials with thickness from 3mm to10mm using a square edge preparation.
• Possibility of using the hot wire process for the filling layer(s).
• Synchronisation of Pulse current and plasma gas for out of position welding.

SEAM PREPARATIONS

3 - 10 mm
8 - 30 mm and higher

8 - 12 mm and higher

8 - 30 mm and higher

3 - 10 mm and higher

With material thickness from 5 mm to 7 mm: v- preparation (30°, 70° or 90°, according to the process combination
and the number of filler layers). By maintaining the correct distance between the torch nozzle and workpiece, this will
ensure that ignition will be trouble free.

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CHARACTERISTICS OF THE WELD POOL
In plasma keyhole welding, the cross-section of the weld pool has a wineglass shape. At the root the weld pool is very
narrow, whilst it widens disproportionately at the top. The rapid cooling of the root and the slower solidification of the
upper area, balance the weld pool.

BEHAVIOUR OF THE WELD POOL

An important fact in examining the influencing factors, is the time difference between the solidification of the weld pool
in the area of the root, and in the region of the surface. The greater the difference the better the control of the weld
pool.

The surface tension and viscosity of the weld pool are basic factors governing its equilibrium.

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FACTORS MAINTAINING THE STABILITY OF THE WELD POOL

These factors can have an effect on the equilibrium of the weld pool:
• Size of the weld pool
• Physical properties of the weld pool
• Seam preparation
• Speed of welding

Size of the weld pool

It is not possible to influence the viscosity of the molten metal. It is, however, possible to control the volume of the
weld metal and its solidification, by specifically modifying the welding parameters, during the welding process.

Physical properties of the weld pool

It is easier to control the weld pool if it meets the following specifications :

• A square edge preparation of 90 degrees
• Diameter of keyhole should be kept as small as possible (between 1 and 3 mm)

Seam preparation

In order not to affect the equilibrium of the weld pool, the welding parameters must be controlled and the seam
preparation consistently good. This consistency has a direct influence on the regularity of the weld. The plasma
nozzles are specially designed for specific maximum currents; on approaching this limit; stray arcs may form,
affecting the plasma arc and the flow of the plasma gas.

Welding speed

If plasma keyhole welding is carried out at a welding speed, which is too slow, this will produce an irregular weld or, in
extreme cases, may cause the weld to fall away. In practice, welding current and gas volume should be set so that
the plasma jet is just strong enough to fully penetrate the workpiece. To obtain a perfect weld, the welding speed
must be adapted to these parameters.

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PLASMA WELDING IN INDUSTRY
As already mentioned, plasma welding is used in diverse areas of industrial production.

The essential areas of application are:

• Food processing industry

• Aviation
• Chemicals / petrochemicals
• Car industry
• Nuclear industry
• Space technology

A wide variety of materials can be plasma welded:

• Carbon steel
• Low alloyed steel
• Stainless steel (Inox)
• Nickel, monel, iconel (Ni-alloy)
• Copper-nickel-iron alloys
• Titanium, tantalum, zirconium
• Aluminium
• etc.

Torch motion devices:

• Longitudinal welding: rail, carriage, ...

• Positioners, turning tables and roller beds
• Precision circumferential seam welding device
• Robots
• Orbital carriage on guide ring
• Orbital welding head
• Special machines
• etc.

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CRITERIA FOR USING PLASMA-KEYHOLE-WELDING
Longitudinal welding presents no particular problems in any position. The synchronisation of the impulse current and
plasma gas needs an appropriate control system.
Two difficulties, however, are associated with orbital plasma welding:

1) Closing of the keyhole

2) Risk of concave penetration from 6 to 9 o’clock. All other positions are easy to master

The flow rate of the plasma gas must be set so as to prevent the material from being ”blown out” and to eliminate
bonding errors or unintentional inclusions.
With a special nozzle, plasma torches can also be used for TIG welding. The centre gas and plasma gas are
controlled separately. The following variations are available when using a power source and a plasma/TIG torch:

- normal TIG method

- TIG double gas method 1
- Plasma /plasma keyhole welding.

Each of these methods can also be used to increase productivity (improved

deposition rate) in combination with the Plasma/TIG hot-wire process.

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PLASMA-WELDING WITH PULSED PLASMA GAS

This plasma-keyhole-welding development allows plasma welding in all positions. The flow speed of the plasma gas is
used to generate the kinetic energy required to fully control the keyhole.

The synchronisation of pulsed welding current and plasma gas reduces linear power input. The volume and therefore
the control of the weld pool can be determined by this ”sewing machine effect”.

Sewing machine effect:

- high current ð fusion of base metal

- low current ð cooling
- heightening of this effect by reduction of plasma gas flow in low current phase
ð precision control of the keyhole

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POWER SOURCE PT 450 BASIC/ STANDARD/ HIGH-END
PlasmaTig – power source

Plasma machine torch

with special water-cooled gas nozzle,
wire guide with adjustment device FWH 4
PlasmaTig-power source PT 450

Standard equipment Necessary options PT 450 -Basic

TIG and Plasma-process Installed robot interface
Constant welding current Cooling unit FK 6 with integrated water flow control
Automatic cooling-unit cut-out Carriage
2-step/ 4-step mode
Plasmagas-control Necessary options PT 450 - Standard
Overtemperature protection Installed robot interface
Thermostat-controlled fan Shielding gas (torch)-control
Mains cable 5 m with plug Cooling unit FK 6 with integrated water flow control
S-sign Carriage
CE-mark
Necessary options PT 450 - High-End
Installed robot interface
Options and accessories Shielding gas (torch)-control
System-Controller FPA 2003/ FPA 9000 Purging gas-control
Installed Lem-Shunt (500A) (onyl with FPA 9000) Cooling unit FK 6 with integrated water flow control
Coldwire feeder Carriage
Installed plate with wire spool uptake
Coldwire guide (automatic-mode) Necessary options Hotwire-application
Wire adjustment device FWH 4 System-Controller FPA 2003/ FPA 9000
Plasma torch TransPocket 200-HD
Gas pressure regulator with measurement tube CO2/ Argon Installed uptake plate for TP 200-HD
Connection lines Installed Lem-Shunt 200A
Wire feeder (hotwire)
Hotwire guide
Process Hotwire machine torch
For mechanized Plasma-/ TIG Hotwire-/ TIG DC-welding Connection lines

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Technical data PT 450
Mains voltage +/- 10% (plus cero-conductor) 3x380V / 400V / 415V 50-60Hz
Mains fuse 380V/ 400V / 415 V (A/ slow) 32 / 25 / 25
Primary continuous current 100% DC (kVA) 17,2
Cos phi 60% ED 0,99
Welding current (A) 3-450
Duty cycle (A) 10 min/ 40° C 100% DC 360
10 min/ 40° C 60% DC 450
Open circuit voltage (V) 50
Operating voltage (V) 0-65
Protection category IP23
Type of cooling AF
Insulation category F
Pilot-current (A) 2 – 30
Plasma/ pilotgas internal adjustable (l/ min) 0 – 10
Shielding gas adjustable (l/ min) 0 - 30
Purging gas adjustable (l/ min) 0 - 30
Dimensions incl. cooling unit and carriage [l/ w/ h] (mm) 900 / 655 / 1120
Weight incl. cooling unit and carriage (kg) 110

Technical data FK 6 Technical data TP200-HD

Mains voltage (V) 230/ 50-60Hz Mains voltage (switchable) 3x380V / 400V / 415V 50 Hz
Throughput (l/ min) 6,5 Mains fuse 380V/ 400V/ 415V (A) 10
Coolant power (kW) 5,5 Power 60% DC (kVA) 6,6
Weight without coolant (kg) 26 100% DC (kVA) 5,3
Max. pump pressure (bar) 4 Cos phi on 150A / 200A 0,98 / 0,99
Coolant volume (l) ca. 6 Efficiency 200A (%) 90
Dimensions [l/ w/ h] (mm) 325/ 305/ 635 Welding current (A) 5-200
Protection category IP 23 Welding current on 60%/ 100% DC (A) 200 / 160
Hotwire voltage (V) 0 – 10
Protection category IP 23
Type of cooling AF
Weight (kg) 20

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SYSTEM-CONTROLLER FPA 2003 TIG HOTWIRE/ MIG-MAG/ PLASMA
Controller (PLC)

Remote control unit FPA 2003-RC

System-Controller FPA 2003 with remote control FPA 2003-RC

lasm
aw
eldingw
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Option:
Thermo-printer and floppy disk drive

Standard equipment Standard equipment

FPA 2003 Orbital System-Controller (PLC) FPA 2003-RC remote control unit (programable) with 10 m cable
Powerful CPU and software • Display with 8 lines and 20 digits
Hardware and software-modularity (open system) • 36 membrane function keys (high-intensity LED’s)
High operation reliability • Language selection
Multitasking operating system • Auto-diagnose-system (error log for rapid error analysis)
Compatible with standard welding power sources • Load welding programs
Mains cable 2,5 m with plug • Start/ stop welding programs
Mountable on carriage • Welding parameter correction
Protection-cover • Display of actual values during
Ease of programming • Manual positioning of axes
Optimum control of process • EMC compatible
Internal memory 200 programs • HF-compliant
Free definable parameter records for each sector
Sector free definable per weld seam (360°) Programable axes
Total addressing/ control of all parameters local with remote control • 1 Linear- or 1 rotation axis
Addressing and control of welding power source
Addressing and control of movements axes Options and accessories
CE-mark Addressing 1 linear- or 1 rotation axis
Addressing wire feeder (TIG/ Plasma)
Area of use Addressing arc length control – AVC (TIG/ Plasma)
Fronius Process Automation - FPA System-Controller Addressing torch oscillation – OSC
are universal and functional useable for welding mechanization Remote diagnosis via modem
and configurable on customized requests Integrated thermo-printer (data-documentation/ printout)
Integrated 3,5” floppy disk-drive (data-documentation/ -transfer/ -saving)
Process Addressing tactile sensor (MIG-MAG)
Software configuration according to the welding process Software ”FPA MANAGER” for on-/ off-line mode (data-docu/ archiv.)
Welding power source TIG/ MIG-MAG/ Plasma

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 Technical data
PLC-controller standard
PLC-controller optional
Dimensions [l/ w/ h] (mm)
Overview of configurations FPA 2003 – power sources and axes
Power source PlasmaTig 450
with option hotwire TP 200 HD
Slide FOU (OSC) Oscillation
Seam tracking
guide sensor
with slide-system
Driving and tracking vehicles FTV and FDV
Addressing welding parameter Mains fuse (A) 4
Addressing 1 axis Mains voltage single phase 230 V 50/ 60 Hz
Addressing purging gas (TIG) Operating temperature (° C) 0-50
Addressing 1 axis Weight FPA 2003 (kg) 16,5
Addressing wire axis (TIG/ Plasma)
Addressing AVC (TIG/ Plasma) Description housing rem. contr. impact-resistant plastic housing
Addressing OSC flame retardance UL94V-0
Addressing modem Remote control - display 8 lines / 20 digits
Addressing printer Degree of protection IP 62
Addressing floppy disk drive Dimensions [l/ w/ h] (mm) 280/ 180/ 100
Addressing guide sensor (MIG-MAG) Weight remote control (kg) 1,5
On-/ off-line ”FPA MANAGER”
600/ 380/ 220
Power sources TIG AC/ DC Power sources MIG/ MAG
with wire feeder KD
Power source
T.I.M.E. TWIN
Slide FCS (AVC)
Arc Voltage Control
FPA 2003
Welding cells/ system-
configurations FWC
Turntables FTT/ FRT/ FRP
Clamping bench FCB
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SYSTEM-CONTROLLER FPA 9000 TIG HOTWIRE/ MIG-MAG/ PLASMA
System-Controller (PLC)

Remote control unit FPA 9000-RC

with cable 10 m

System-Controller FPA 9000

Standard equipment Standard equipment

Combination Industrial PC and PLC/ CPC-control system PLC/ CPC-control
High operational reliability • Addressing and control of welding power source
Ease of operation • Addressing and control of movements axes
Choice on language for operator surface • Programable axes
Optimum control of the welding process - 2 Linear axes
Integrated ink-jet printer (A4) - 1 Rotation axis
Remote control unit FPA 9000-RC with 10 m cable - 1 Wire axis

Industrial PC/ software Remote control unit FPA 9000-RC

• Data input • Display with 8 lines and 20 digits
• Data recording (welding programs) • 36 membrane function keys (high-intensity LED’s)
• Process-visualization • Load welding programs
• welding data documentation • Start/ stop welding programs
• Intel Pentium 166MHz - processor • Welding parameter correction
• 32 MB-RAM - working • Display of actual values during
• 12,1“ TFT-display • Manual positioning of axes
• 2,1 gigabyte hard disk • CE-mark
• 3,5“ floppy disk drive • EMC compatible
• WIN95/ NT - operating system • HF-compliant
• powerful software
• function keys for operation Area of use
• for handling no PC-knowledge necessary Fronius Process Automation - FPA System-Controller
• Error indication via text on screen (IPC) are universal and functional useable for welding mechanization
and configurable on customized requests

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Options Accessories
Addressing double head station (2 welding systems) Customized mechanical construction
Addressing arc length control – AVC Gantry
Addressing torch oscillation – OSC Driving vehicle
Addressing oscillation function on linear axes (cross slide) Column and boom
Addressing purging gas (Plasma) Turntable/ positioner
Addressing 2 rotation axes (switch-over) Cross slide-system
Remote diagnosis via modem AVC-slide
Installed optical operating condition indication OSC-slide
Installed oscilloscope board - welding current Camera-system
Installed video board in combination with a camera-system for visual Seam tracking-system
arc length control on IPC-screen Power source
Installed CD-ROM drive (techn. documentation) Wire feeder
Installed temperature measurement-system Machine torch
Installed actual value recording on file Uptake and adjustment devices
Installed Bore-to-bore - software Connection lines
Installed Network connection Preheating device
Customized software

Process
TIG AC/ DC, TIG AC/ DC Cold-/ Hotwire, MIG/ MAG, Plasma

Technical data FPA 9000 Technical data FPA 9000-RC

Mains fuse (A) 16 Operating temperature (° C) 0-50
Mains voltage single phase (V/ Hz) 230/ 50-60 Description housing rem. control impact-resistant plastic housing
Servomotor-controller DC 4 Q +/- 0-10 V flame retardance UL94V-0
Dimensions FPA 9000 [l/ w/ h] (mm) 600/ 600/ 1820 Degree of protection IP 62
Weight (kg) w. cable, w. rem. con. 150 Dimensions FPA-RC [l/ w/ h] (mm) 280/ 180/ 100
Mains cable FPA 9000 5 m with plug Weight remote control (kg) 1,2

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