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Plasma and TIG processes used in automatic applications
The term plasma applies to gases at temperatures
exceeding 3,000 °C (5,000 °F) at atmospheric pressure.
On the temperature scale, it can be regarded as the fourth
state of matter after the solid, liquid and gaseous states.
The plasma arc is now widely used in the steel, The isotherm diagram shows clearly
that the energy distribution is strongly
chemical and mechanical engineering industries.
modified within the plasma arc :
It’s a powerful cutting and welding tool.
It is generally accepted that the plasma welding • the 16,000 to 24,000 °C
(29,000 to 43,000 °F) temperature
process is the major technological advance in
zone is outside the nozzle,
inert gas welding (the TIG process).
• the 10,000 to 16,000 °C
(18,000 to 29,000 °F) temperature
zone is entirely transferred to
Plasma arc: high temperatures, the workpiece and causes the
a concentrated arc, better productivity. keyhole effect (penetration of
the workpiece).
PLASMA
Temperature °C (°F) 1
With a free arc (TIG process), the
4,000 to 10,000
(7,000 to 18,000) highest temperature zone is too
10,000 to 16,000
(18,000 to 29,000) close to the cathode or tungsten
16,000 to 24,000 2 3
(29,000 to 43,000) to be usable.
24,000 (43,000)
4
The 4,000 and 10,000 °C
1 - plasma gas 3 - shielding gas
2 - plasma arc 4 - keyhole effet (7,000 and 18,000 °F) temperature
PLASMA ARC - 150 A - 28 V
• The arc spreads very little on leaving the strongly zone is narrow in plasma welding
cooled nozzle.
• The 10,000 to 16,000 °C (18,000 to 29,000 °F) compared to TIG welding where
temperature zone is transferred to the workpiece in
concentrated beam. the zone is much wider with a
characteristic “bell” shape. This zone
TIG
is not without its uses: it causes
Temperature °C (°F) A
surface melting of decreasing depth
4,000 to 10,000
(7,000 to 18,000)
relative to the plane of the joint,
10,000 to 16,000
(18,000 to 29,000) B providing a gentle transition from the
welded area to the base metal.
A - shielding gas B - the free arc
2
The plasma is made up of excited ions, electrons, atoms or molecules; it occurs in
nature, generated by lightning, for example. Since about 1960, the word plasma
has gained a new meaning, referring to the high-energy state caused by constricting
an electrical arc by means of a diaphragm or nozzle.
Advantages of plasma
Thickness limitation
• Speed of operation and low Maximum thickness which can be welded, flat with butt-jointed surfaces, in
distortion. one pass with 100 % penetration. Maximum thickness that can be welded
is reduced for:
• Reduces post-weld straightening • vertical up and horizontal welding positions,
operations. • small diameter and very thick tubes.
Depending on the thickness of the material, using keyhole plasma welding,
• Low buildup reduces polishing deconfined plasma welding, TIG or microplasma welding.
and grinding procedures. 0.06 0.5 1.0 2.5 3.0 6.0 8.0 10 mm
(0.04) (0.1) (0.12) (0.24) (5/16) (0.4) (in)
• Weld metal integrity- keyhole
Microplasma
fuses parent metal. Deconfined plasma or TIG
Microplasma Keyhole plasma
• High-quality weld integrity and
Deconfined plasma or TIG
appearance. Keyhole plasma
Deconfined plasma
• Reduction in the preparation
Keyhole plasma
times for assemblies by
Stainless steel type 304: Ar, Carbon steel: Ar, Ar + He
eliminating bevelling for Ar + H2 (5 %) Back of joint shielding
gas: identical
to shielding gas
thicknesses up to 8 mm (5/16”). Titanium: Ar, Ar + He
70° 80°
• Excellent reproducibility typically
used with automatic equipment. 8 mm (5/16”)
• Produces a perfect weld bead 1.5 mm
(0.06”)
1 mm
(0.04”)
2 mm (5/64”) 1.5 mm (0.06”)
overlap due to perfect control of
70° 70° 75°
the relevant parameters.
> 8 mm
(> 5/16”)
1.5 mm 1.5 mm 5 mm
(0.06”) (0.06”) (0.2”)
2 mm (5/64”) 1.5 mm (0.06”)
Integrating the two processes into a single installation can improve productivity by
as much as 30 to 50 %.
0.1
6 (0.24) 25-30 (10-12) 40 (16)
(3.94) Plasma
8 (5/16) 15-20 (6-8) 25 (10)
1 5 8
(0.04) (0.2) (5/16) Thickness: mm (in)
Advantages of the In the plasma + TIG process, the Thicknesses less than 3 mm (0.12”)
plasma + TIG process plasma arc first melts the entire can also be welded perfectly but only
thickness of the joint by using a a single-torch TIG process is used.
• High quality of plasma weld.
strongly confined plasma, which only Thicknesses greater than 8 mm (5/16”)
• 30 to 50 % increase in
affects the appearance of the back of require an additional single-torch
productivity.
the joint. The trailing TIG arc 250 mm - TIG filling pass.
• Can be adapted to varied boiler
300 mm (10 - 12”) behind is equipped
and tank-making processes
with a magnetic oscillation system and The plasma + TIG process is
due to its great flexibility.
wire feed. This magnetic oscillation, specially designed for large
coupled with a trailing gas shield, capacity stainless steel boiler
TIG weld work:
ensures a perfect weld finish.
• length > 3 meters (10’),
The plasma + TIG process • diameter > 2.2 meters (7’),
works on thicknesses between the manufacture of large
3 and 8 mm (0.12 and 5/16”). stainless steel tubes or pipes
welded in one piece.
Plasma weld
4
Aluminium welding using the automatic TIG process
Variable polarity TIG or squarewave AC ensures continuous
deoxidation, a high-quality weld bead with total control of
the weld pool for terminating the weld bead.
Thickness limitation for the TIG process used for aluminium welding.
Maximum thickness which can be welded, flat* with butt-jointed surfaces, in one pass with 100 % penetration:
1.0 2.5 3.0 6.0 8.0 mm
Aluminium TIG AC: Ar or Ar + He
(0.04) (0.1) (0.12) (0.24) (5/16) (in)
Aluminium TIG DC He: 100 % He
TIG DC He
TIG AC * (in horizontal position, the maximum thickness is reduced)
thicknesses up to 8 mm (5/16”), it needs only one pass with no preparation. 1.6 (0.06) 100 13 75 (30) 110 (43) 30
2.0 (5/64) 150 13 75 (30) 110 (43) 30
Operations to be carried out: 2.5 (0.1) 210 13 75 (30) 130 (51) 30
3.0 (0.12) 220 14 65 (25) 200 (79) 30
• mechanical oxide remover, 4.0 (5/32) 250 14 45 (18) 200 (79) 30
5.0 (0.2) 250 14 45 (18) 220 (87) 30
• mechanical support using a backing bar is required for the weld pool. 6.0 (0.24) 300 15 30 (12) 220 (87) 30
8.0 (5/16) 360 15 18 (7) 140 (55) 30
Current application: longitudinal welding on seamer bench. One pass with 100% penetration, butt-jointed, position flat.
* l/min = 2 cfh approximately
5
Plasma welding in the workshop
Use plasma or TIG processes for flat position, or circular
welding of stainless steel, noble metals, steels or aluminum.
Manufacture all types of products for the petrochemical,
agriculture/food processing, aeronautical industries, etc.
6
Circular welding with column and
boom on rotator or positioner.
7
Vertical tank and boiler work
Use plasma or TIG processes for horizontal welding
of stainless steel, noble metals, steels or aluminium.
Manufacture storage equipment for agriculture/food
processing, petrochemical industries, etc...
Vertical welding
In order for a workpiece to be welded on a rotator, it has
to be rigid enough (relationship between diameter, thickness
and dimensions) to ensure satisfactory stability while welding
takes place. For cases where rigidity is not sufficient, or costly
(vessel sizing tools), difficult or even impossible to improve,
welding can be carried out “in the vertical axis”; the workpiece
is rotated using a horizontal turntable and the torch remains
static in the horizontal welding position. This allows very large
dimension workpieces to be produced without the use of
complex tools.
Turntable capacities:
5T (11,000 lb), 10T (22,000 lb) and
15T (33,000 lb).
For other requirements, please
do not hesitate to contact us.
8
Plasma welding for prefabricated pipe work
9
MANAGER plasma installation
This installation meets the highest quality standards for welding
and productivity for industries as diverse as boiler-making using
stainless steels, aeronautics using noble metals, chemical
engineering, energy production, processing and transport
as well as prefabrication of pipelines, etc.
The MANAGER control unit is programmable and controls both the process
and all peripheral equipment whatever the complexity of the application.
It is a decentralised and modular control and management system. The
programming and control unit box display all messages in multi-lingual MEC4 SP7
cleartext on 4 lines of 20 characters.
10
NERTAMATIC 450 plasma or TIG installation
Multi-purpose welding installation for the following processes
in automatic applications:
• DC TIG with smooth or pulsed current
• AC TIG with variable polarity (squarewave),
• DC plasma with smooth or pulsed current,
This equipment is offered in several versions.
Process control
• 50 welding programs (voltage, current, wire speed, movement)
Equipment
• Cleartext LCD screen display
• Parameter modification while welding
• Cycle start/stop, manual control of gas/wire, arc voltage control
Machine add-ons
• Movements, mecacycles, PLCs etc
To order:
standard offer LC 03-012 standard offer LD 04-032
DC TIG and AC/DC TIG versions: this installation can The DC plasma version uses automatic plasma welding
assemble butt-jointed stainless steel panels up to and can assemble butt-jointed 8 mm (5/16”) carbon steel,
3 mm (0.12”) thickness and light alloy steels up to stainless steel, titanium or alloy steel in a single pass
8 mm (5/16”) thickness (DC TIG under helium) and without the need for bevelling.
6 mm (0.24”) (AC TIG under argon) in a single pass.
TIG Plasma
To order:
standard offer LE05- 020 Each installation memorizes and
manages its own welding
Basic installation: parameters. The unit is equipped
The TIG + plasma installation is
with a digital control in order
made up of two NERTAMATIC
to synchronise welding torch starts
450 installations:
and stops, and to control the
• a plasma installation with
speed and length of weld.
SP7 torch and arc voltage
This digital control memorizes
regulation,
and manages the movement
• a TIG installation with MEC4
parameters.
torch, arc voltage regulation,
wire feed, arc oscillation and
gas protection carriage.
12
Add-ons
Suitable for all machine types:
• video surveillance,
• oscillation or magnetic deviation of TIG arc,
• hot wire feed.
Arc deviation
This technique is used to
AVC (Arc Voltage Control) and wire
electrically deflect the TIG arc,
feed autonomous units
which considerably increases the
These devices can be used to update older automatic
heat-affected zone along the TIG and plasma welding installations, and to create
weld axis, and increases speed simplified installations for manual welding stations.
by 30 to 50 % for thicknesses of
less than 2 mm (5/64”). This facility is particularly suited to 5
3
the continuous welding of thin tubes formed from strip, 1
cable conduit, electrical resistance shielding etc. i.e: all
mass-produced parts welded without filler metal. 2
4 AVC
1 - power control box
Arc oscillation 2 - harness
3 - remote control unit box
An extension of the arc deviation technique described above, 4 - torch location
5 - motorised sliders for voltage control
arc oscillation is used to deposit metal over areas up to 6 - filler wire feeder
2 4 FIL
13
Microplasma
The microplasma process is used for welding fine
thicknesses of noble metals, such as stainless steel, inconel,
titanium, zirconium, alloys of silver and gold etc. It is suitable
for electric and electronics components, small containers,
metal filters and tool repairs as well as watchmaking,
jewellery and medical industries.
Auto
1 2 3 4
5 6 7 8
14
Deconfined plasma
The INVERTER 180 plasma unit is specially built for
automatic welding using the deconfined or soft plasma
process. It is used for intensive production and is suitable
for all machine types. The most recent applications are
the production of melt-runs, small weld beads or very
repetitive welding.
The installation can also use the control arc double-flux TIG process using smooth
or pulsed current. Plasma is an evolution of the TIG process which brings many
opportunities for increasing your productivity.
Equipment
2 3
4
35 mm
1 1
15
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