FORM 11-815-B

INSTRUCTIONS for SEPTEMBER, 1974

PT-1'1 (Series 2)
PLASMA NEEDLE ARC TORCH

Table of Contents Page

I.In tro ductio n ........................... 1
Equipment .............................................. 1 - 2
Adjustments and Operation
A. P r e c a u t i o n a r y I n fo r m a t i o n . . . . . . . . . . 3
B. P ilot A rc Sy ste m .. .. .. .. .. .. .. . .. .. .. 3
C. Pi lo t A rc Operat ion . .. .. .. .. .. .. .. 4
D. T ra n sfe r re d A r c O p e r a t ion . . . . . . . . 4
E. S e l e c t i on o f O r i f i c e an d E le c t r od e
Sizes .................................................... 5
F. T o r ch A sse mb ly ................... 7
G. Operating P rocedures ............. 8
H. W e l d i n g C o n d i t i o n s . . . . . . . . . . . . . 10
IV. P ro cedure s fo r We lding Foils a nd
HISTORY COPY Thin Metals ............................ 14-15

MCD V. Mod i ficat io n fo r B ra zing a nd

Cutting ........................................ 16
DO NOT REMOVE VI.
VII.
M a i n t e n a n c e . . . . . . . . . . . . . 16-17
T r o u b l e s h o o t i n g P r o c e d u r e s . . . 18-19
VIII. Replacement Parts Data ................. 20

I. INTRODUCTION II. EQUIPMENT

The PT-12 (Series 2)* Plasma Needle Arc Welding Torch, A.PT-12 Torch Assembly
Part No. 993906, has a current carrying capacity of 75 The PT-12 torch assembly, Part No. 993906, includes the
amperes on 100% duty cycle and 100 amps on 60% duty following items:
cycle. It is designed for use with the PWC-5 control/power
Part No. Quantity Description
supply and a conventional (CC) power supply. The dimen-
sions of the PT-12 torch are shown in Figure 1. 634580 2* Gasket
634803 Gauge and Assembly Tool
For additional information on plasma needle arc welding 634800 No. 6 Gas Cup Assembly
process, request booklet F-52.540, "New Developments and 634801 1 No. 8 Gas Cup Assembly
Applications in Manual Plasma Arc Welding", from your 634514 2* 3/32-in. Centering Bushing
Linde supplier. This booklet supplements the information 634601 1 3/32-in. Collet
contained in instruction booklets supplied with the equip- 634625 1 3/32-in. Electrode
ment. 635277 2* .086-in. Orifice Insert

* One assembled into torch; balance are spares.

HISTORY COPY
Be sure this information reaches MCD WELDING
the operator. You can get extra
copies through your supplier.
DO NOT REMOVE PRODUCTS
 .16

20_*/

IN 1-I

I6

________ 5 u

im
74 APPROX.

FIG. 1 - PT-12 Torch Dimensions

B. Spare Parts Kit C . Op tio n al Ac c es s o r ies Description Part No.

Although the PT-12 is a ruggedly-built torch employing high WC-5 Water Cooler 183F15
quality components, some replacement of parts may be Torch Holder Assembly (Refer to Fig. 12) 635562
necessary after prolonged use. To minimize any possible Two Piece Orifice Inserts:
"down time", it is strongly recommended that the following Insert Body (Common) 633723
parts be purchased as a complete spare parts package under .030-in. Orifice Tip 633893
Part No. 635840. .052-in. Orifice Tip 633809
.086-in. Orifice Tip 633724
Fillet Welding Inserts: (Also see Table 1)
.030-in. Orifice Insert 993496
.05 5-in. Orifice Insert 633500
No. 5 Gas Cup Assembly 598618
Part No. Quantity Description No. 7 Gas Cup (Short) 598619
634768 1 Collet Body and Knob Assy. No. 12 Gas Cup 633623
85W49 1 "0" Ring Tip Cleaners 751F00
187W01 1 "0" Ring No. 65 Nozzle Compound 08N65
634756 1 Retainer Green Plastic Shield 737F28
634626 1 Spring Headband 737F39
634599 1 Collet Nut Magnifier Lenses, 2.5 power, 2-in. w x 4.25-in. lg.
634800 3 No. 6 Gas Cup Assembly (used with either item below) 737F58
634801 3 No. 8 Gas Cup Assembly Soft Frame Welding Goggle, Stationary Front # 42 639104
635282 3 .040-in. Centering Bushing Soft Frame Welding Goggle, Lifting Front # 43 639105
634543 3 1/16-in. Centering Bushing
634514 3 3/32-in. Centering Bushing D . Consumables Requ ired
635287 1 .040-in. Collet
634602 1/16-in. Collet 1. Plasma orifice gas - Argon is used at a nominal flow rate
635281 10 .040-in. Electrode of 1.5 CFH, at 20 psig. Actual flow rate depends on the
634624 5 1/16-in. Electrode orifice used.
634625 5 3/32-in. Electrode 2. Shielding gas - Argon, argon-hydrogen or argon-helium
635279 2 .030-in. Orifice Insert mixtures are used. Flow rates range from 15 CFH to 40
635278 2 .052-in. Orifice Insert
635277 2 .086-in. Orifice Insert
2

CAI depending upon material being welded, the shield-
ing gas and the cup size. Input pressure to the control
should be 20 psig.
3. Cooling water - A supply of 1 qt./min. at a pressure of
40 psi is required. If the available water supply is not at
these conditions, a WC-5 water cooler should be used. A
zero back pressure drain must be provided for water dis-
posal.
III.ADJUSTMENTS AND OPERATION
It is assumed in the following paragraphs, that the welding
equipment has been set up as described in the booklet cover-
ing the welder control.
WARNING: Before operating the torch, be sure to read the
following safety precautions. Failure to do so may result in
personal injury and death.
A. Precautionary Information:
3. Hydrogen is a combustible gas and can be an explosion
hazard. Keep open flames away from cylinders contain-
ing hydrogen and hoses used to carry hydrogen. Keep
open flames away from the torch when purging. Never
use 0-1, 0-2 or 0-5 argon-oxygen mixture with hydrogen;
the mixture is explosive!
4. Use normal precautions to protect against arc flash and
heat from the pilot arc effluent.
PILOT ARC
SWITCH
WATER
FLOW
SWITCH -
* TORCH W ILL BE SEVERELY D AMAGED IF PILOT
ARC IS IN IT IATED WITHOUT COOLING WATER FLOW.
* * USE 3-I/2 R OT AT ION S FO R 30 T IP ON 3 /32"
ELECTRODE (SEE FIG. III
FIG. 2 P ilo t Arc System
3
F-11-815
1. Eye and Face Protection - For welding with transferred
arc currents up to 5 amp., spectacles or other types of
eye protection with a No. 6 filter is recommended. Al-
though face protection is not normally required for this
current range, its use depends on personal preference.
For welding with transferred arc currents from 5 amps.
to 15 amps., a full-face light green plastic shield is recom-
mended in addition to eye protection with a No. 6 filter.
A suitable combination for the full-face protection is a
headband, Part No. 737F39, and light green plastic
shield, Part No. 737F28.
For welding with currents of 15 amps. to 100 amps., a
conventional weldor's helmet with at least a No. 8 lens is
recommended.
2. As is customary in electric welding, due consideration
should be given to the fact that open-circuit voltage may
be hazardous to the operating personnel.
5. For further details, refer to F-52-529, "Precautions and
Safe Practices for Electric Welding and Cutting", obtain-
able without charge from any Linde office.
B. Pilot Arc System
Fig. 2 shows a simplified electrical schematic of the pilot
arc power system. This system includes a separate D.C.
power supply, an indicator light and a water flow safety
switch. Note that proper initiation of the pilot arc and set-
back adjustment o f the electrode are dependent upon the
TURN KN OB COUNTER
CLOCKWISE
I- 1 /2 R OTA TI ONS **
AFTER ELECTRODE
TOUCHES, i.e .,
WHEN PILOT LIGHT
GOES OUT.
use of the indicator light to determine the instant at which
electrical contact is made between the electrode and the
torch orifice insert. If the indicator light is not used, the
pilot arc can still be initiated but the setback will usually be
much too short. Thus, as the electrode heats up during
transferred arc welding, it will become slightly longer with
the possibility that the tip might touch the orifice insert
again and become damaged.
The indicator light is connected in parallel with the torch
and power supply which, when first turned on, gives a high
voltage. The indicator light, therefore, glows brightly.
However, as soon as the torch electrode is screwed down to
touch the orifice insert, a maximum of current flows. At
this point the power supply voltage drops to near zero, not
enough for the pilot light which then goes out to indicate
the moment of electrical contact. It's the same as an elec-
trical short circuit except that the system is designed to
limit the amount of current flow to safe values.
After contact between the electrode and orifice insert is
made, counter-clockwise rotation of the torch cap for 1 1/2
complete revolutions will establish a pilot arc of the proper
length for long term trouble free operation.
RIGHT
POINTED CLEAN ELECTRODE
CLEAN SMOOTH ORIFICE
PILOT ARC BRIGHT ZONE
HOT PLASMA
(CONDUCTIVE 1
FIG. 3 Pilot Arc Operation
C. Pilot A rc Operation
The pilot arc, when operating properly, heats the orifice
argon to form a conductive gas plasma jet as can be seen in
the left illustration in Fig. 3. It is this conductive plasma
which makes it possible to transfer an arc to the workpiece.
The plasma jet also stabilizes and directs the transferred arc.
If the pilot arc should shift internally for any reason, the
orifice gas will not be heated adequately to form the re-
quired stabilizing plasma. The gas will emerge relatively
cold and non-conductive. In this event it will be difficult,
or impossible, to transfer an arc to the workpiece. Arcs
which do transfer will be off-center or unstable.
Conditions which lead to unstable pilot arcs are blunt, ir-
regular or oxidized electrode tips, and soot or burrs on the
orifice itself. Both the orifice insert and the electrode tip
should be cleaned, as noted in Section VI and Figure 11,
when these defects occur.
D. Transferred Arc Operation
Once the pilot arc is in operation, initiation of the welding
or transferred arc can be readily obtained by turning on the
welding power supply. The torch orifice is brought to within
approximately inch of the workpiece, the plasma jet is
WRONG
OXIDIZED ELECTRODE
SOOT OR BURRS ON ORIFICE
N COLD GAS
( NON- CONDUCTIVE )
4
 F-11-815

aimed at the intended starting point and the power supply
contactor is activated by a foot switch. The plasma jet pro-
duced by the pilot arc permits instant transferral of the weld-
ing arc to the weldment without any need for high frequency
power.
E. Selection of Orifice and Electrode Sizes
Before assembling the torch, select the proper orifice and
electrode sizes for the intended welding application.
Table 1 lists both standard and special accessories (orifices
and shielding cups). The standard series is intended for
welding joints where accessibility is not a problem. One
piece orifices are shown with a variety of shielding cup
sizes. Two piece orifices are also available for greater
economy where their reduced current capacities can be
permitted. The special accessories include small orifice
bodies and shielding cups which are preferred when
welding in confined joints such as Tee fillets. Current
capacities for these orifices are listed in Table 2. Recom-
mended electrode sizes are listed in Table 3. Typical manual
welding conditions wh ich can be used are li sted in
Tabl es 4 th rough 8 .

Table 1 Orifices and Shielding Gas Cups.

Relative Sizes of Shielding Gas Cups

STANDARD ACCESSORIES SPECIAL ACCESSORIES

One Piece Orifices Fillet W eld Orifices

Dia. Part No. Dia. Part No.

.030" 635279 .030" 993496
.052" 635278 .055" 633500
.086" 635277
Two Piece Orifices Part No. Shielding Gas Cups

Tip D ia. (For use with above orifices)

.030" 633893 Size Part No.
.052" 633809 No. 5 598618
.086" 633724 No. 7 (short) 598619
Body Insert (common) 633723

Shielding Gas Cups

Size Part No.
No. 6 634800
No. 8 (short) 634801
No. 12 633623
* Use 1 or 2 ex tr a gask ets 1 63 45 80) if it is desire d to exten d g as c up l engths.

5
 (1)
Table 2 Arc Current Capacities for Orifices

Orifice Arc Current Capacities (DCSP)

Melt-in Mode Keyhole Mode

Type Max. Current Orifice Argon Max. Current Orifice Argon

Dia. Part No.
Amps cfh, M in. Amps cfh, Min.
Standard .030 635279 25 0.6 40 1.0
Standard .052 635278 55 1.0 75 2.0
Standard .086 635277 100 1.5 120 3.0

Two-piece body 633723

Tip .030 633893 20 0.6 35 1.0

Tip .052 633809 45 1.0 65 2.0
Tip .086 633724 85 1.5 100 3.0

Fillet Weld( 2) .030 993496 25 0.6 N.R.

Fillet Weld( 2) .055 633500 55 1.0 N.A.

) For m ax im um or if i c e lif e, m ai n ta in c o nt in uo us shi el d f low wh en ever p i lo t a rc is o pe r at ing . A l so re f er to i nst r uc ti o ns o n

p urg i ng of weld ing sy ste m ( S ec. 1 11, P aragr ap h G) an d to T ab l e 3 f or p rop er e lec tr od e siz es.

(2) T he se o rif ice s are i nt end ed f or in crea se d acc essibi l ity f or maki ng sm a ll f illet weld s where short ar c l eng th s, ap pr ox im at ely
1/8- in., are req uired . W hen u sed, the stand ard electrode extensi on, 1- 7/ 8, mu st be shortened by 3/16- in.

N .R. N o t r e c om m e n d e d .

Table 3 Recommended Electrode Sizes" )

Electrode Dia. (2)(3) Max. Current

Pilot Arc Current( 4)

(in.) (amps, DCSP} Initiation Run

(amps) (amps)

.040 15 5 3

1/16 40 8 5
3/32 100 151 12 7

( 1) E l e c t r o d e s ar e 2% t h o r i a t e d t u ng s t e n, ce n t e r l e s s g r o u n d .
( 2) On new or inf req uently used machine s, long er lif e of orif ices a nd electrode s can be
ob ta in ed by u si ng t he ne xt l a rg er el ec tro de siz e f or the i nt en de d op er at ing c ur re nt .
13) For to rch start ing of p ilot arc , use e le ctr od e size whic h is larg er th an orif ice d iame ter.
P ro p e r se tb ac k is ob t ai n ed by rot a ti ng c ol l et b od y k n ob 11 / 2 r ot at i on s co un te r -
c lo ck wi se af ter e lectr od e touche s. Se e Fig ure 2.

( 4) Af ter ini t iat io n of the p il ot ar c, r u nn i ng c ur re nt s c an b e red uc ed , if de sir ed , to t he

va lues sho wn t o r ed uc e p l asm a ef f lue nt and or if i ce er osio n.
( 5) For p rolong ed u se at cur ren ts above 70 amp s, i t i s r eco mme nd ed t ha t t he 3/ 32- in.
diam eter electrode tip to b e ground to a 30 d eg ree includ ed ang le . S etback should be
changed f rom normal 11/2 turns up to 31/2 turns.

6
 PT-12 F-
11-815

F. Torch Assembly .
1. To assemble the torch, begin by placing the centering
I DIMPLE 2 DIMPLES
bushing for the particular electrode size (See Figs. 4 and
13) into the orifice. Tapping the orifice will help the
bushing to settle properly on its seat. The end of the
bushing with the smallest hole should be closest to the
orifice.
2. Insert the retainer, 634756, to hold the centering bushing
in its proper place. The upper end of the retainer should
.040-in I/16-in.
be flush with the end of the orifice insert. If it is not, PART No.-635282 PART No.-634543
remove both the retainer and bushing and reassemble
until correct fit is obtained.
3. Screw the assembled orifice insert into the torch head
until the flanged threaded portion bottoms on the metal
shoulder of the torch head, as shown in Figure 5, thus
3 DIMPLES
assuring good cooling contact. Use the gauge and as-
sembly tool, Part No. 634803, (See Fig. 6) as a wrench
to achieve a hand tight fit.
4. Replace rubber gasket, Part No. 634580. This gasket
acts as a thermal barrier to prevent damage to the moulded
torch body from heat transmitted through the gas cup.
3/32 -in.
5. Screw the ceramic cup/gas lens assembly on finger tight. PART No.- 634514
6. In sert the proper electrode into the collet body and
knob assembly, Part No. 634768. The gauge and as-
sembly tool, is used to measure the electrode extension FIG. 4 Centering Bushing Size Identification
and to tighten th e collet nut as shown in Figure 6.

SHIELDING GAS

GASKET-634580
PROVIDES GAS SEAL BETWEEN
TORCH HEAD AND CUP. INSTALL
ONLY AFTER INSERT HAS BEEN
TIGHTENED.

ORIFICE INSERT
MUST BOTTOM AGAINST
TORCH BODY FOR GOOD
COOLING.
ORIFICE INSERT

GAS LENS SCREENS MUST

LIE FLAT AND SNUG AGAINST
CUP AND ORIFICE INSERT.

FIG. 5 Assembly of Lower Part of Torch

7

WRENCH END FOR
ORIFICE INSERT
_ . .. I II YE =
' wp m a I m a
,} sim
HG. 6 Use of Gauge and Assembly Tool 634203
7. Place the spring, Part No. 634626. into the top half of
the torch body as shown in Figure 7. Screw in the elec-
trode assembly. Do not tighten it excessively.
8. Check for gas tightness of the torch by setting the orifice
flow to 1 CFH and closing the orifice hole with your
finger or a stopper as shown in Figure 7. If the meter
float drops to zero, the system is properly sealed. If gas
continues to flow, the system is not properly sealed and
one or more "0" rings should be replaced.
NOTE: To prevent contamination of the orifice gas, a
special material is used in the hose assembly. This material
will stiffen and may crack under impact at temperatures
below 40 F. if not protected.
G.Operating Procedure
The operating procedures for argon, argon-hydrogen, or
argon-helium are basically the same and are covered to-
gether. Minor differences which occur in the operation
conditions are pointed out.
Shielding Gas
Various percentages of argon-hydrogen mixtures can be
obtained by blending argon and cylinder premixes of 5%
hydrogen in argon (H-5) or 15% hydrogen in argon (H-15).
The flowmeter settings for such mixtures are given in the
instruction booklet supplied with the welder control.
Settings for shielding gas mixtures containing from 0 to
100% helium in argon are also given in the booklet.
ELECTRODE AND
COLLET BODY KNOB
ASS'Y
Gas and Water Adjustments
1. Turn on the water recirculator, if one is being used, or
the main water supply valves. Water input of 1 qt/min
and 40 psig is required.
2. Open the valves on the orifice gas and shielding gas cy-
linders. Adjust the regulators on these cylinders to 20
psi. (lower pressure will result in torch damage).
3. Adjust the orifice gas flow by opening or closing the
flowmeter valve. This gas must flow continuously to
purge the system. Proper argon flow rates for the various
orifice sizes are shown in Table 2.
4. Adjust the shielding gas flows to the proper values as
shown in Table 4 through 8.
Arc Starting - Pilot Arc
1. Turn on the pilot arc switch. The pilot arc indicator
light should glow brightly indicating that water flow is
adequate and the eleCtrode and orifice are not in elec-
trical contact.
2. Before igniting the pilot arc, allow the orifice gas to flow
for a few minutes* to purge the pilot arc chamber. The
pilot arc is ignited by rotating the knurled knob on the
torch head in a clockwise direction until mechanical
contact is made between the electrode and the orifice
insert and then immediately withdrawing the electrode
A f e w mi nu t es a r e sa t is f act o r y f or a m ach i n e t h a t h as b een i n
f r eq u e n t u s e Fo r a n ew m a c h i n e, or o n e t h a t h a s h a d i t s g a s
h os e l i nes exp os ed to ai r f or m or e t ha n a f ew ho ur s i t wil l b e
n ecess ar y t o p ur ge al l g as ti n es f o r at l ea st 1, 5 mi n ut es bef or e
i g ni t in g t he pil ot a r c. Th is fl u sh es th e li nes o f f ree a ir and als o
dries them of condens ed m oisture. T o avoid this pr oblem it i s
best to keep the hose lines pressurized with inert gas during shut
downs. Also, allow a small flow (112 CFH) of orifice gas to flow
c on t in uo us l y to ke ep t h i s cr i t i c al li n e i n op t im um c on di tio n.
8
 r e -s . c F-
11-815

"0" RING - 187W01

LEAKAGE CAN OCCUR IF IT
IS DAMAGED. REPLACE AND
LUBRICATE FOR FREE BUT
SEALING MOTION. *

SPRING - 634626
MUST BE IN PLACE TO PREVENT ORIFICE GAS
ARCING DAMAGE TO THREADS OF
COLLET BODY. IF SPRING IS LOST POWER CABLE
OR DAMAGED, REPLACE WITH
NEW SPRING.
NOTE;
TOP a BOTTOM HALF ARE
ELECTRICALLY INSULATED.
"0" RING - 85W49
LEAKAGE CAN OCCUR IF
WATER "IN"
SHIELD GAS
IT IS DAMAGED. REPLACE
AND LUBRICATE.*

4
\-- TEST PLUG FOR FINGERTIP)
PLACED OVER ORIFICE SHOULD
CAUSE ORIFICE FLOW TO DROP
TO ZERO. IF IT DOES NOT,
FIND AND ELIMINATE LEAK.

ii
Use No.65 Nozzle Compound 08N65.
Apply One Drop, Then Wipe Off To
Leave a Thin Film.

FIG. 7 - Assembly of Upper Part of Torch

9
by turning the knob 1-1/2 turns counter-clockwise.
Watch the pilot arc indicator light as the knob is being
turned clockwise. As soon as the light goes out, indicat-
ing that the electrode is shorted to the orifice insert,
retract the electrode by turning the knob counter-clock-
wise_ Using the pilot arc indicator in this manner will
avoid torch damage which could be caused by use of ex-
cessive force when contacting the orifice insert with the
electrode. Note that the pilot arc indicator light will
relight dimly when the pilot arc is ignited.
Welding or Transferred Arc
1. Position the torch so that the orifice is approximately
1/4 inch above vise or clamp holding the workpiece.
2. Depress the foot switch which will cause the arc to trans-
fer to the vise. Note that the ground return clamp of the
power supply must be attached to the workpiece or
holder.
3. Adjust the current set knob on the control to obtain the
desired transferred arc current. (See following tables of
welding conditions).
4. Begin welding by holding the torch approximately 1/4
inch above the workpiece and canted at a slight forward
angle for visibility of weld.
5. Move the torch along the seam at a uniform speed. Note
that variations in arc length do not have a significant
effect on the weld and that the arc is stable even at the
lower currents.
Arc Shutdown
1. Release the footswitch to extinguish the transferred arc.
To protect the weld zone, shielding gas should continue
to flow for at least 2 seconds after the arc goes out.
2. To shut down the system, first shut off the pilot arc and
allow the electrode to cool for 10 seconds or more be-
for turning off the shield gas and water flows.
H.Welding Conditions
There are two basic techniques which can be used for
manual plasma arc welding; melt-in mode and the keyhole
mode_
Melt - in Mode
In this mode, puddle melting occurs softly, just as in con-
ventional welding except that the arc is more stable, it can
be aimed in a particular direction, and relatively long (1/4"
and more) arc lengths can be used. Because of the long arc
lengths and the protection of the electrode behind the ori-
fice, the addition of filler wire becomes a simple, trouble
free operation. There is no possibility of fouling the elec-
trode or of leaving tungsten deposits in the weld.
Tables 4 through 6 show typical welding conditions which
can be used for welding butt, lap fillet, and Tee fillet joints
10
using the melt-in mode of operation. Normal arc length is
about 1/4-in. although longer or shorter arc lengths can be
used. It should be noted, however, that when making Tee
fillet joints on these metals of the order of 1/16-in. or less,
use of the special fillet welding orifices will be desired. As
shown in Table 1, the use of the fillet welding orifices
permits torch access for operation at shorter arc lengths
(118-in.) in such confined areas to produce the smallest sizes
of fillet welds.
When welding metal foil or very light gauge metals special
procedures are required and are described in Section IV.
Keyho le - Mode
This mode of welding is entirely new for manual welding.
It is produced by welding with relatively high but carefully
controlled orifice flows (See Tables 7 and 8) wherein the
plasma jet actually pierces the weld puddle_ While the torch
is moved at a uniform speed, molten metal flows from the
front of the keyhole to the rear where it reforms into a con-
tinuous weld. Keyhole welding is preferred on the heavier
gauges because it assures full, reliable penetration. The
presence of a keyhole during welding is visual proof that
full penetration is being obtained. It is not necessary, as in
tig welding, to stop, turn the weldment over and inspect for
penetration. It is an especially useful technique for making
root passes in pipe joints and other "blind" weld joints
where inspection of the back side of a weld is difficult.
Keyhole welding also produces welds at greatly reduced arc
currents which are about half as wide as those made with
the melt-in or tig modes or welding. Thus, weld distortion
and the tendency towards weld cracking is substantially
reduced.
To initiate the keyhole it is best to dwell at the starting
point at reduced currents until a fair sized weld puddle is
formed. Before full penetration is reached, increase the
welding current to the full value (See Tables 7 and 8) and
start moving the torch forward. The plasma jet will then
pierce the puddle to form the keyhole. Uniform continuous
speed is required to control the size of the keyhole which,
in turn, presets the width of weld penetration. Fast speeds
form small diameter keyholes; slow speeds form large dia-
meter keyholes with wide underbeads. Do not stop torch
motion or else the keyhole will become too wide.
To slop the keyhole at any lime, reduce the welding current
at which point the keyhole will close due to insufficient
melting capacity. Orifice flow rates can then be reduced to
values typical of the "melt-in" mode in order to smooth out
the puddle depression. A small amount of filler wire can
also be added at this time. See notes (1) and (2) of
Tables 7 and 8 for additional comments on the keyhole
welding technique.
 F-11-815

Table 4 Butt Joints (Melt-in Mode)

Arc Current Welding Orifice

Thickness Shielding Ga s
(amps, DCSP) Speed (ipm)
Dia. 1 Argon (cfh)

ST AINLE SS STEE L
M
0.001 0.3 5 .030 0.5 1% H2 -Ar

.003" ) 1.6 5 .030 0.5 1% H2 -Ar

.005" 1 2.4 5 .030 0.5 1% H2-Ar

.010 6 8 .030 0.5 1% H2-Ar

.020 16 10 .030 0.5 1% H2-Ar

1/32 25 10 .030 0.5 1% H2 -Ar

.050 13 4 .030 0.5 5% H2-Ar
1116 45 10 .052 1.0 5% H2-Ar
3/32 90 10 .086 1.5 5% H2-Ar
1/8 100 8 .086 1.5 5% H2- Ar

CA RBO N S T E E L

1/16 80 10 .086 1.5 Argon

3/32 100 6 .086 1.5 Argon

1/8 100 4 .086 1.5 Argon

TITANIUM

0.003 (1) 3 6 .030 0.5 Argon

0.008 5 5 .030 0.5 Argon

0.015 8 5 .030 0.5 Argon
7 0.5
0.022 13 .030 Argon

COPPER -

0.003" ) 10 6 .030 0.5 75% He-Ar

( 1) Flanged hut, joi nt.

( 2) Shielding gas fl ows:

Argon or argon- hy dr og en mix t ur es 1 S - 2 5 ef h

H el i um o r he l i um - ar go n m i x t u r e s 3 4 0 e ll,

11
 Table 5 Lap Fillet Joints (Melt-in Mode)

Thickness Arc Current(1) Orifice Shielding Gas(2) Filler Wire

(in.) (amps, DCSP) (Dia.) Argon (cfh) (Dia.)

STAINLESS STEEL
1/16 30 .030 0.6 5% H2-Ar .030

3/32 40 .052 1.0 5% H2-Ar .030

1/8 50 .052 1.0 5% H2-Ar 1/16
3/16 100 .086 1.5 5% H2-Ar 1/16
1/4 100 .086 1.5 1/16
5% H2-Ar

CARBON STEEL

1/16 40 .052 1.0 Argon .030

3/32 50 .052 1.0 Argon .030

1/8 60 .086 1.5 Argon 1/16

11) W elding sp eeds 6- 10 ipm

121 S hielding gas f lows 15- 20 efh

Table 6 Tee Fillet Welds (Melt-in Mode)

Thickness Arc Current( 11 Filler Wire

Orifice
Shielding Gas(2)
(in.) (amps, DCSP) (Dia.)
(Dia.) I Argon (cfh)

STAINLESS STEEL
1/16 35 .052 1.0 5% H 2-Ar .030

3/32 50 .052 1.0 5% H 2-Ar .030

1/8 80 .086 1.5 5% H 2-Ar 1/16
3/16 100 .086 1.5 5% H 2-Ar 1/16
1/4 100 .086 1.5 5% H 2-Ar 1/16

CARBON STEEL

r
1/16 70 .086 1.5 Argon .030
3/32 90 .086 1.5 Argon .030
1/8 100 .086 1.5 Argon 1/16

(1) Weld ing speed s 6- 10 ipm

(21 Shielding g as f lows 1 5 - 2 0 cf h

12
 I-I2
F - 11 - 815

Table 7 Butt Joints (Keyhole Mode)1)

Thickness Arc Current(2) Orificei 3) Shielding Gas(4)

(in.) (amps, DCSP) (Dia.) Argon (cfh)
STAINLESS STEEL (300 series)

1116 2 .030 1.0 1% H2-Ar

3/32 5 .052 1.8 1% H2-Ar
1/8 5 .052 2.2 1% H2-Ar
0 .070 3.0 1% H2-Ar
3/16 75 .070 5.0 1% H2-Ar
9 .086 8.0 1% H2-Ar
0
A-286
1/16 I 35 .030 1.5 1% H2-Ar
,
INCONEL 718

3/32 40 .030 1.5 1% H2-Ar

i
HASTELLOY X

1/16 22 .030 1.5 1% H2-Ar

CHROMALLOY

1/16 25 .030 1.0 1% H2-Ar

TITANIUM 6 A1-4 Va
1/16 36 .030 1.5 75% He-Ar
CARBON STEEL

1/16 25 .030 0.6 Argon

3/32 70 .052 1.5 Argon
1/B 80 .052 2.0 Argon

( 1) F i l l e r w i r e c a n b e a d d e d w h e n k e y h o l e w e l d i n g 1 1 1 6 - i n . m a t e r i a l s , b u t f o r 3 / 3 2 -i n . a n d g r e a t e r t h i c k n e s s e s i t i s
p r e f e r ab l e to k e y h o l e w i th o u t f i l l e r . A l ig h t co s m e t i c p as s ( m e l t -i n mo d e ) w i t h o r w i t h o u t f i l le r , c a n t h e n b e m a d e f o r
o p t i m u m s u rf a c e a p p e a r a n ce w h i l e r e t a i n i n g n a rr o w b e a d w i d t h s a n d m in i m u m d is t o r ti o n .
( 2) S o m e o f t h e s e "k e y h o le " a r c c u r r e n t s a n d o r i f i c e g a s f l o w r a t e s a r e g r a t e r t h a n t h e n o r m a l " m e l t - i n " v a l u e s . W h e n
g o in g b a ck to t h e me l t -i n mo d e , i . e . , f o r co s m e t ic o r m u l ti p a s s we l d in g , b e s u r e t o d e r a te th e o r i f i c e s a s s h o w n to a v o i d
o r if i c e b u r n o u t .

O r i f i c e D i a m e t e r (i n . ) M ax. C ur r en t ( am p s , DC SP ) Mi n. O ri f ice F lo w ( A rg on , C F H )
.0 30 25 0.6
.0 52 55 1.0
.0 70 80 1.3
.0 86 1 00 1.5
( 3) W h e r e t w o o r i f i ce s i z e s s h o w n f o r s a m e m a t e ri a l th i ck n e s s , u s e s m a l l e r o n e f o r o u t -o f -p o s i t i o n w e l d i n g , l a rg e r o n e f o r
f as t e r d o wn h a nd we ld i ng .
( 4) S h ie ld i n g g a s f l o w s ar e 1 5 . 2 0 c f h f o r A r g o n o r A r g o n 1 % H yd r o g e n mi x t u r e ( 1 - 1 - 1 ). 1 1 -5 m ix t u r e i s n o t r e c o m m e n d e d f o r
o u t- o f - p o s i t i o n w e ld i n g . H e li u m o r h e l i u m a r g o n f l o w s a r e 3 0 - 4 0 c f h ,

13
 Table 8 Butt Welds on Aluminum( I } (2

Mode Arc Current131 Orifice

Thickness Filler Dia.
(in.) (amps, AC) (Dia.) Argon (cfh)
(in.)
1/8 Melt-in 45 .052 1.5 3/32 4043
1/8 Keyhole 45 .086 5.5 none
3/16 Root Pass
Keyhole 75 .086 6 none
Cover Pass
Melt-in 65 .086 2.5 3/32 4043

(1h F u l l p e n e t r a ti o n in ti g h t b u t t j o i n t s , 1 / 4 - i n , ar c l e n g t h , we ld i n g s p e e d s 6 - 1 0 i p m , t y p e 1 1 0 0 a n d 6 0 6 1 a l u m i n u m .
(2) H e l iu m s h i e l d i n g , 3 0 cf h , N o . 6 c u p
(3h U s e 3 I3 2 - i n . d i a m e t e r 2 % th o r i a l e d e l e c t r o d e , 4 5 d e g r e e p o i n t e d t i p , 1 0 a m p D C S P p i lo t a r c .

IV.PROCEDURES FOR WELDING FOILS AND A. Fixturing

THIN METALS
To successfully weld light gauge and foil thickness metals
below 0.030-in., careful procedures must be followed. The
weld puddle behaves quite differently in these thin mate-
rials. Surface tension strongly determines the shape of the
molten metal, regardless of whether the weld position is
overhead, vertical, or flat. Weld defects leading to irrepa-
rable damage are largely related to poor shielding or fixtur-
ing because of their effects on the surface tension of melted
joint edges. Extra care in cleaning of parts is also needed
because oxides or grease films affect surface tension and arc
characteristics.
Common oversights in foil welding procedures include:
1. Excessive joint gaps -- which cannot be bridged by the
melted edges.
2. Inadequate clamping -- which allows joint warpage during
welding.
3. Fingerprints or oil films -- which alter the degree of melt-
ing attained at a given current level.
4. Weld oxidation or base metal oxides which prevent
good wetting and attachment of the molten films.
5. Incomplete weld puddle support -- which allows nicking
at the free ends of a butt joint.
The basic requirement when welding thin metals is to make
sure that both joint edges are in continuous contact and
that both edges melt simultaneously to fuse together into a
single weld puddle. Separation between the joint edges
before or during welding will cause the edges to melt sepa-
rately and remain apart.
Illustrations of tolerances for joint fitup and fixturing are
shown in Figures 8 and 9 for metal thicknesses of 0.030-in.
and less. Figure 8 shows the tolerances for joint gap and
mismatch, as well as the fixture dimensions for hold down
clamps and the backup groove. The tolerances are listed in
relation to the material thickness. Thus, for a square butt
joint, a maximum joint gap of 0.2 x (t = 0.03-in.) = 0.006-in.
is permitted. This is a very small gap indeed. It shrinks to
only 0.001-in. for a foil thickness of 0.005-in.. The fixturing
for such weldments must be precision tooling. Increased
latitude in butt joint fixtu ring tolerances can be obtained
by modifying the joint - i.e., flanging the edges. The turned
up edges act as replaced filler material to fill the gap and
assure melt contact with both sides of the joint. They also
stiffen the joint edges to minimize warpage from heat build-
up during welding.
Figure 9 shows the fitup and fixturing tolerances for edge
joints. Note that on every count, the tolerances are much
greater than those for butt joints. Because of this wide
tolerance, the edge joint is the easiest and most reliable
joint for welding. Successful welding of foil thickness as-
semblies is greatly assured whenever it is possible to convert
the joint into some form of edge joint.

14
 ri-14
F-11-815

A
ir
t

_LB
I
t ______

BUTT GAP MISMATCH min max

CLAMP B A C K U P *
JOINT "A"max " B" max SPACING GROOVE
TYPE MC "D"
min max
SQUARE 0.2t 0.4t lot 20t 4t 16t
FLANGED ;VA' 0.61 It 151 301 10t 24t

Gus Backing, Either Argo or Helium is Required

if if
Flanging Of Butt Joints is Recommended For Thickness Below 0.010-M

FIG. 8 Butt Joint Weld' Fixturing (Foil and Sheet Up to 0.030" Thick)

if Wrinkling Of Joint Edges Begins At St

FIG. 9 Edge Joint Weld Fixturing Tolerances (Foil and Sheet up to 0.030" Thick)

15
B . Optica l Aids
Welds on thin metal parts may be so small that they can not
be seen clearly with the naked eye, therefore, it is difficult
to determine whether joint fitup is and remains satisfactory.
Some form of optical magnification is usually needed for
the applications. In general, magnifications which enlarge a
joint to at least 0.020-in. thickness will be adequate for
most people. Thus, for parts having a 0.010-in. edge thick-
ness, a 2X magnification would be desired, or a 4X magnifi-
cation for a 0.005-in. edge thickness.
C . Procedures for Cleaning Workpiece
Strict attention to surface cleaning becomes increasingly
important as metal thicknesses approach those of foils. The
parts to be welded should be cleaned shortly before welding.
Once cleaned, it is vitally important that joint surfaces
remain untouched and clean. The presence of a fingerprint
can alter the arc behavior on foils to such an extent that
welding stops in the zone of the fingerprint. It is good prac-
tice to store recently cleaned parts in plastic bags (Glad
Bags, etc.) until they are ready for immediate welding.
Hands or fingertips should be covered with plastic or latex
film gloves when handling parts.
Solvent degreasing can be used for the cleaning of oily or
greasy surfaces. Vapor condensation of trichlorethylene
type solvents probably leaves the least residual film on the
surface. When vapor degreasing apparatus is not available,
immersion or wiping with disposable swabs dipped in solvent
are acceptable procedures. Suitable solvents include trich-
lorethylene, N1-6 methyl chloroform or acetone.
Rust, scale and oxides can be removed by pickling or acid
cleaning; preferably with acids such as hydrochloric, nitric,
singly or mixed. Wash thoroughly in hot water after pick-
ling and dry as quickly as possible. Precautions should be
taken to ensure adequate ventilation and protection of the
operator from the solvent fumes or pickling solutions.
V. MODIFICATION FOR BRAZING AND CUTTING
The plasma needle arc welder can easily be modified for
non-transferred arc operation to permit brazing, heating and
cutting non-metallics, i.e., quartz, ceramics, etc. Such items
are heated by hot gas emanating from the torch orifice
which is heated from an internal arc or non-transferred arc.
The PT-1 2 needle arc torch can be used for non-transferred
arc operation up to 60 amperes.
Conversion to the non-transferred arc mode is accomplished
by connecting the pilot arc and transferred arc power
supplies as follows:
I-
PWC 5
POWER -
SUPPLY CONTROL
1DC) ELECTRODE
AMPS.
1+
1
0
WORK 0 -50 AMPS-
ELECT,
JUMPER
IS
ORIFICE
Remove Work Lead
WORKPIECE
FIG. 10 Modification for Brazing and Cutting
A. Procedure
a. Place jumper cable as shown in Figure 10 between the
WORK terminal on the DC power supply and the pilot
arc connection of the torch. A No. 8 stranded wire is
suitable for this intermittent usage. The torch handle
can be pulled back to expose the existing soldered con-
nection of the pilot arc cord (red lead, See Fig. 13). The
jumper wire should he soldered at this same water cooled
junction. Be sure to cover the joint with insulating tape
to prevent a short circuit between nearby metal parts.
b. For maximum heat transfer, use an 0.086-in. diameter
orifice, a 3/32-in. diameter electrode and orifice argon
flows of 5 cfh to 10 al. Place the orifice within 3/8-in.
distance from the workpiece as plasma gas temperatures
decrease rapidly with longer distances.
c. If a strong cutting action is desired, use the 0.030-in. or
the 0.052-in. diameter. orifice with argon orifice flows of
10 to 30 cfh or more. The cutting is effective for manual
operations on thin metals, i.e., below 1/16-in. and on
non-metallics such as quartz or asbestos.
B. Operation
The main line switch will activate the power, gas and water
solenoids. The pilot arc is then initiated in the usual way,
to supply an initial 10 amps of non-transferred arc current.
The pilot arc by itself is the lowest non-transferred arc
current (5 to 10 amps). Additional current can be varied up
to 50 amps for a total of 60 amps.

VI.MAINTENANCE (Refer to Figs. 5, 6, 7, 11, and 13).
When the torch is in proper operating condition the pilot
arc will be stable. A pulsating, erratic or generally unstable
pilot arc indicates that the electrode tip is dirty, contami-
nated or misshapen. Normally, this should not occur more
frequently than once every 4 to 6 hours of operating time.
If it does, check the entire gas system for loose connections
or other possible sources of entry of impurities. In addition,
check pilot arc starting procedures, as given in the booklet
supplied with the control. Avoid excessive contact pressures
which can damage the tip. The procedure for disassembling
the torch is as follows:
1. Shut off the pilot arc and main power. Allow the torch
to cool for about a minute.
2. Unscrew the electrode holder assembly by rotating the
knurled plastic cap counter-clockwise until it can be
withdrawn from the torch.
3. Inspect the electrode tip. It should be free of burrs, soot
or burns. However, slight discoloration along the mid-
point of electrode length is normal. Regrinding or clean-
ing may be performed with the electrode in the holder
assembly or, to minimize equipment downtime, the elec-
trode may be replaced with a spare electrode and re-
dressed separately. For minimum downtime, stock com-
STEEL WOOL
(FINE GRADE)
.005".015"DIA.
FLAT ON TIP
PROPER ELECTRODE TAPERING
FIG. 11 Electrode and Orifice Insert Maintenance
F-11-815
plete spare electrode-and-holder assemblies.
4. To remove the electrode from the holder assembly,
loosen the collet nut using the slots on the gauge and
assembly tool, Part No. 634803, as an open end wrench.
(It is suggested that both ends of the electrode be pointed
so that it is only necessary to reverse it to obtain a fresh
tip). For optimum performance, a 45 taper to an .005-
.015-in. flat is recommended. Proper electrode tapering
is illustrated in Figure 11. Grinding can be done manually
using a fine grit abrasive wheel. When reassembling the
unit use the length of the gauge and as-
sembly tool (See Fig. 6) to determine the proper amount
of electrode extension and then tighten the collet with
the tool.
5. Inspect the electrode holder assembly "0" ring. Part No.
187W01 (See Fig. 7). It should be free of nicks or
scratches and lightly coated with a silicon grease for lu-
brication to maintain a tight seal. To replace the "Cr
ring, cover the threads with one turn of tape to prevent
nicking the fresh "0" ring.
6. Unscrew the ceramic cup from the torch. Inspect the
cup and fine mesh gas lens screens. The screens should
be flat, held in place by the split ring and without any
burn holeS or soot. If any faulty conditions exist replace
the gas lens/cup assembly.
ORIFICE INSERT
OXWELD TIP CLEANERS
STANDARD SET
(PART No. 75/F00
REMOVE SOOT AND BURRS
FROM THESE SURFACES.
*FOR ARC CURRENTS ABOVE 70 AMPS. USE 30
T IP ON 3/32" ELECTR ODE
(SEE TABLE 3, NOTE 5)
17
7. Remove the orifice insert by engaging the four teeth on
the gauge and assembly tool with the slots on the orifice
assembly and turning counter-clockwise, as viewed from
the orifice end.
8. Remove the retainer by inverting the orifice insert and if
the centering bushing does not fall out easily along with
the retainer, tap lightly.
9. Remove any accumulated soot from the centering bush-
ing by blowing or rubbing with a.cloth or with a small
brush. DO NOT USE ABRASIVES! Clean the center
hole of the bushing by pushing the electrode through it
a few times.
4 which illustrates the marking used to identify the
various sizes of centering bushings.
11. Inspect the inside of the orifice insert with a strong
light. An accumulation of soot on this surface can cause
an erratic and unstable arc. Any soot should be
removed with fine steel wool wrapped around a No. 42
drill, or with a cotton swab, as shown in Figure 11. To
minimize downtime the entire orifice insert may be
replaced and the fouled insert cleaned at a later time.
12. Clear the orifice with a tip cleaner from OXWELD Tip
Cleaner Set, Part No. 751 F00, as shown in Figure 11.
Avoid enlarging the hole size.

10. Inspect the centering bushing. The appearance of any 13. Inspect the "0" ring, Part No. 85W49, inside the torch
cracks, chips or noticeable wear from repeated cleaning head with a strong light. It should be free of grease,
indicates that the bushing must be replaced. If in doubt nicks or scratches.
as to the size of the replacement bushing, refer to Figure 14. To reassemble the torch, see Section III-F

VII. TROUBLESHOOTING PROCEDURES

Trouble Possible Cause Remedy

a. Pilot ar c un stable 1. Orifice insert is Clean torch parts and repoint

dirty or electrode electrode as described in Section
is eroded. V1-4,9-12, and Figure 11.

2. Electrode setback too Rotate knob on hack of torch

short. 1-1/2 turns CCW. See Table 3
and Figure 2.

b. Pilot arc unstable or difficult
to ignite, and electrode quickly
becomes contaminated.
I. Insufficient or contaminated orifice Check orifice gas delivery pressure
gas flow. and flow rate. Check for gas leakage
and defective torch "0" ring seals
as described in Section VI-5, 13,
and Figure 7.
2. Inadequate purge of orifice Continue purge for 15 or more minutes
gas lines. before striking pilot arc. See Section
III G, Pilot Arc Starting-2.

c. Pilot arc spot leis noisely, electrode Torch connected for reverse Check torch cable connections. See
balls on end, centering hushing polarity. Figure 2.
melts or cracks, orifice insert has
bright sputtered surface on outside
face.

d . Pilot arc goes out. Water pressure switch momen- Eliminate pulsing of water pressure
tarily deactivated by loss of by using a water recirculator.
water pressure.

18

Trouble Possible Cause
e. Orifice erodes quickly. 1. Insufficient orifice gas flow.
2. Orifice insert not being cooled
properly.
3. Electrode setback too short.
4. Inadequate shield gas.
f. Arc does not transfer to 1. Ground clamp not connected.
work.
2. Orifice gas flow inadequate
or shielding gas not flowing.
3. Torch to work distance too
long.
4. No voltage across electrode
and workpiece.
g. Arc transfers at an "odd" 1. Orifice or electrode is
angle. fouled.
2. Centering bushing size
incorrect
h. Torch spring softens. Resistance heating of spring.
(Excessive electrode exten-
sion).
FIG. 12 Torch Holder, Part No. 635562 (Optional)
19
F-11.815
Remedy
See Remedy for b. 1.
Insert must bottom against torch body
for good cooling (See Figure 5). Torch
body and orifice insert contact sur-
faces must be clean and smooth.
See Remedy for a. 2.
At least 15 cfh shield gas required.
(See Tables 4-8.) Shield gas and orifice
gas required whenever pilot arc is on.
Connect ground clamp to workpiece
or fixture.
Increase orifice gas flow to proper
flow (See Table 2). Check gas
pressure (20 psig required). Also
see a. I. and b. I.
Shorten torch to work distance to
1/2-in. for all argon shielding and
1/4-in, for mixed gases.
Check for open circuit voltage of
power supply.
See a. 1.
See Figure 4
Assure adequate thread engagement
of collet body b y proper use of
gauge for setting electrode extension.
 r: t.- C
0
Cz z
rn 0
to a z
0
n SUPPLIED
z CO
PART Na QTY DESCRIPTION
P m 634800 I Nab GAS CUP ASSEM.
635277 1 ORIFICE INSERT (.086")
0 634580 2 GASKET
ELECTRO DE & CO LLET 634803 I GAUGE B ASSEM. TOOL
CO 0 BODY KNOB-634768 634514 I CENTERING BUSHING
Includes
O 5/16" I.D. "0" RING-187W01

z 3/32" dia. ELECTRODE-634625

3/32" COLLET-634601
COLLET NUT-634599

HANDLE-635442 -Connect Leads. Wrap Connection

SPRING -634626
TORCH BODY ORIFICE GAS With Several Layers of Black
HOSE a LEAD ASSEM-634778 Polyethylene rape
( INCLUDES-634809) WIRE CLAMP
53N04
5/16"1.D."0" RING-85W49

RETAINER-634756
GASKET-634580

3/32' CENTERING
BUSHING-634514 SHEATH-598615

ORIFICE GAS HOSE

ASSEM.- 634809 (Yellow)
(INCLUDED IN-634778 )
No.8 GAS CUP ASSEM,
634801 POWER CABLE ASSEM.
Includes 635291 (Black, Red --
RETAINING RING-634538
(7)SCREEN-634540 WATER IN HOSE NOTE SERIES 1 TORCH (634829) CONTAINED A JUMPER
A S S E M - 5 9 8 5 7 5 ( Black, - - - - -
h < C= E 0
HOSE ASSEMBLY (635834) FOR USE WITH C 200
-

Bieck Band) OR C-2000 POWER SUPPLIES IN A PWM-7 (600104)

086" dia. ORIFICE INSERT OR PWM 7T (600106) INSTALLATION.
635277
PILOT ARC CORD
598577(Red)

SHIELDING GAS HOSE

A SS E M - 59857 3 (Black/

FIG. 13 - PT-12 (Series 2) Torch, Part No. 993906