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Plasma Cutter Versus Other Methods Of Welding And Cutting

Brandon Hale ELEC 6750 Spring 2004

Questions

In which application is a plasma arc welder not used? How does one achieve laser like cuts to a plasma cutter?

Outline

Definition Of Terms History Companies Switching To Plasma Cutters Plasma Cutting Variables Adding Laser Like Cuts To A Plasma Cutter Aerospace Applications

Definition Of Terms

TIG Tungsten Inert Gas LBW Laser Beam Welding EBW Electron Beam Weld PAW Plasma Arc Welder

History

1950 1957 1962 1963 1968 1972

TIG Welding Conventional Plasma Cutting Dual flow Plasma Arc Air Plasma Cutting Water Shield Plasma Cutting Water Muffler For Plasma Cutting

Bohlen, K. Ed, et al. Hypertherm's plasma cutting history. http://www.hypertherm.com/technology/plasma_history.html

History

1977 1980 1983 1985 1990

Underwater Cutting Low Amp Plasma Cutting Oxygen Plasma Cutting Oxygen Injected Plasma Cutting High Density Plasma Cutting

Bohlen, K. Ed, et al. Hypertherm's plasma cutting history. http://www.hypertherm.com/technology/plasma_history.html

Companies Switching To Plasma Cutters

Benefits of Plasma Cutting:


Faster Cutting Speed No Pre-heat Cycle Smaller Cut Width Smaller Heat Affected Zone Portable Unit Cost

Miller Electric Mfg. Co. Plasma Cutting Buyers Guide. Illinois, 2004

Companies Switching To Plasma Cutters


lets you plasma cut at any location, on any job site and in any country without worrying about opening and manually linking the machine or damaging the machine from incorrect hookup. -Miller Electric Mfg Co

Miller Electric Mfg. Co. Plasma Cutting Buyers Guide. Illinois, 2004

Plasma Cutting Variables

Voltage Nozzle Air Flow Rate

S. Ramakrishan, M. Gershenzon, F. B. Polivka, T. N. Kearney, and M. W. Rogozinski, Plasma Generation for the Plasma Cutting Process, IEEE Trans. on Plasma Science, Vol. 25, p.937-946, 1997.

Adding Laser Like Cuts To A Plasma Cutter

One Input:
2.45 GHz Microwave Continuous-Wave Magnetron Power Supply

A. Al-Shamma, R. Wyllie, J. Lucas, and J. D. Yan, Atmospheric Microwave Plasma Jet for Material Processing, IEEE Trans. on Plasma Science, Vol. 30, p.1863-1871, 2002.

Adding Laser Like Cuts To A Plasma Cutter

A. Al-Shamma, R. Wyllie, J. Lucas, and J. D. Yan, Atmospheric Microwave Plasma Jet for Material Processing, IEEE Trans. on Plasma Science, Vol. 30, p.1863-1871, 2002.

Adding Laser Like Cuts To A Plasma Cutter

Benefit:
The cost savings means that the microwave plasma torch is a better choice for material cutting and welding when precision is not critical. - Ahmed I. Al-Shammaa

A. Al-Shamma, R. Wyllie, J. Lucas, and J. D. Yan, Atmospheric Microwave Plasma Jet for Material Processing, IEEE Trans. on Plasma Science, Vol. 30, p.1863-1871, 2002.

Aerospace Applications

TIG
Acceptable Welds For Copper Excessive Porosity And Poor Fusion For Aluminum

EBW
No Fusion Between Aluminum Weld Elements

K. Richardson, B. Stein, P. Shah, and N. Isaacs, Process Development of Electrode-Tab Welds for Aerospace, Lithium-Ion Cells, IEEE Conference, Vol. 1, p.651-658, 2000.

Aerospace Applications

PAW
Best Fusion On Aluminum Inconsistent Welds

LBW
Best Weld For Aerospace Applications Requires Oxidation of Aluminum No Preparation For Copper

K. Richardson, B. Stein, P. Shah, and N. Isaacs, Process Development of Electrode-Tab Welds for Aerospace, Lithium-Ion Cells, IEEE Conference, Vol. 1, p.651-658, 2000.

Conclusion

Plasma Cutters Have Led Companies In A Direction To Benefit From Costs Savings As Well As Quicker Project Completion Times However, Plasma Cutting Yields Numerous Benefits, It Is Not Applicable For All Jobs

Questions and Answers

In which application is a plasma arc welder not used?


Aerospace

How does one achieve laser like cuts to a plasma cutter?


Take a microwave continuous-wave magnetron for the power supply

References

Bohlen, K. Ed, et al. Hypertherm's plasma cutting history. http://www.hypertherm.com/technology/plasma_history.html Miller Electric Mfg. Co. Plasma Cutting Buyers Guide. Illinois, 2004 A. Al-Shamma, R. Wyllie, J. Lucas, and J. D. Yan, Atmospheric Microwave Plasma Jet for Material Processing, IEEE Trans. on Plasma Science, Vol. 30, p.1863-1871, 2002. S. Ramakrishan, M. Gershenzon, F. B. Polivka, T. N. Kearney, and M. W. Rogozinski, Plasma Generation for the Plasma Cutting Process, IEEE Trans. on Plasma Science, Vol. 25, p.937-946, 1997. K. Richardson, B. Stein, P. Shah, and N. Isaacs, Process Development of Electrode-Tab Welds for Aerospace, Lithium-Ion Cells, IEEE Conference, Vol. 1, p.651-658, 2000.

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