If you are looking for a welding process that combines precision and versatility, then it’s plasma welding. It has made great significance in the ever-evolving welding technology with its many applications and ease of operation.
It is a welding process that was used for special low-current in heavy industries. It’s also known as an advanced welding technique to produce high-quality welds with high accuracy. And that is why it has gained prominence in various industries and many companies use plasma welding for many applications.
So, if you want to know more about plasma welding, its applications and benefits, you have come to the right place. This blog will explain whatever you need to know.
Understanding Plasma Welding
Plasma welding works at high temperatures and uses ionised gas (argon or a mixture of argon and hydrogen) known as plasma. It then creates an electric arc between the workpiece and the welding electrode. The intense heat generated by the plasma arc will melt the base metal and cut it with high accuracy and precision.
The usage of argon, the inert gas, will create a protective surrounding the arc and weld zone, so the weld doesn’t react with the oxygen present in the air and you can get high-quality welds.
Plasma welding Uses
Because of the corrosion-free welds, plasma welding is used widely. The common applications include a range of industries where optimisation of production volume consistency and reduced downtime are keys.
It is particularly used in automotive, aerospace, shipbuilding, industrial machinery design and petrochemical industries. Whenever you want to build pipes, tanks, metal structures, engine parts, or cutting tools, then you can think of plasma welding.
Plasma welding can be used on almost all materials and it can help improve productivity, quality, and efficiency of various manufacturing and construction processes.
Steps Involved in the Plasma Welding Process
The person who uses plasma welding needs to follow 3 steps:
- Prepare parts for welding: All the welding supplies that are needed for welding need to be cleaned to remove contaminants like rust, grease, or paint residues.
- Set up the plasma welding equipment: Setting up the equipment involves mounting the electrode, connecting the power supply and shielding gas cables, and checking all safety parameters. It also includes having a power source, welding torch and cooling system.
- Welding parameters and settings: before starting welding, you need to set the thickness and other welding specifications so that you can get the welds as per requirement. Not all can arrange the specification unless you are a professional welder with a thorough knowledge of all the parts and their functionalities.
Benefits
The intense heat generated at the arc will help you get welds that are of high quality. You can get accurate and fine cuts with high precision. No matter what kind of thickness you want, you can achieve it by using plasma welding. Other benefits include:
- Focused arc that can help with accuracy, deep penetration, reduced heat-affected zone, fast travel speeds and less arc wander
- Protected electrode which allows it to maintain its condition
- Arc transfer without high frequency - will not interfere with control equipment
- Arc control - can help you fine-tune tip hole size, electrode setback and gas flow rates
- Gas selection - you can use a variety of gases
- Plasma welds are free from defects such as porosity, cracks and inclusions.
- Creates a solid fusion of materials and ensures a solid, homogeneous connection.
- Various settings in the plasma arc let you control different parameters and thicknesses.
- In plasma welding, you get precise cuts which means there is less mess produced during the welding. It also simplifies post-processing operations.
Limitations of Plasma Welding
While the benefits are far too appealing, there are also a set of limitations for plasma welding. There is so much equipment involved in the welding and the installation and maintenance costs are also high compared to the other welding process.
Due to the high temperature, the plasma welding also requires a cooling setup to prevent distortion. Unless you are a professional who can handle the equipment, it’s hard for a beginner to handle the whole plasma equipment setting.
In a nutshell, plasma welding is an advanced process that should be handled by experienced hands. However, you can get high-quality welds that are no match to the ones produced by other welds. It is a dependable and accurate welding procedure that can give you the desired outcome.
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