Plasma arc welding is a type of welding process that uses high-temperature plasma to melt metal and fuse the pieces together. The plasma welding process was developed in Sheffield, England by engineers from the engineering company Arthur Martin and Sons Ltd. in 1920. It was first used industrially in 1925 by Hobart Brothers Limited of Tapton House, Derbyshire, who sold them as “Hobart Arc-Welders”. The process was originally invented for cutting steel with an electrified blade, but has since been adapted for welding as well.

Where It’s Used and Its Advantages

Plasma welding is used for a variety of applications, including construction work, mining and fabrication. It can be used to weld thick or thin material, as well as both ferrous and non-ferrous metals. The process is quicker than other welding methods, such as gas metal arc welding (GMAW) or fusion welding, because it does not require filler materials or heat input from another source after the initial weld has been made.

The process begins with the creation of an electric arc between two pieces of metal, usually by means of a hand-held torch. The current passes through a gas such as helium or hydrogen and ionizes the gas when it reaches a high enough temperature, creating a hot plasma that melts the metals at the welded area. Welding is performed in either a straight line or circular fashion depending on the type of equipment used. Circular systems are more common because they have fewer gaps between the joints being welded, but both methods can be used for either straight or circular welding.

The plasma arc welding process is quicker than other fusion welding processes because it does not require additional heat input from another source after the initial weld has been made. The high temperatures at which the welded area cools are sufficient to fuse the metal together. In addition, there are no filler materials required with this process; only the two pieces of metal being welded need to be joined by an electric arc. Because of these factors, it’s often used for construction work or other situations where speed and efficiency are important.

The plasma arc welding process has a few advantages over other fusion welding processes such as resistance spot welding and gas metal arc welding (GMAW). First, it does not require additional heat input after the initial weld has been made; this makes it faster than other methods that require reheating. Second, because there are no filler materials required with this process, it can be more economical than other fusion welding processes that require filler materials. Third, it has a high penetration rate and can weld through thick or thin material with little difference in quality; this makes it an ideal process for welding steel of all types.

Plasma Welding Equipment

The plasma arc welding equipment used depends on the type of application being performed. If straight welding is required, then either a linear system or a circular system may be used. Linear systems use long electrodes to reach over large distances while circular systems have short electrode tips that are closer together and can reach within a small radius. Linear systems are commonly used for construction work, while circular systems tend to be more common in fabrication and industrial applications.

The basic components of plasma arc welding equipment include the power supply unit (PSU), gas cylinder, torch head assembly, control panel and cable reel. The PSU is at the heart of the system and provides voltage to heat the plasma. It includes one or more transformer rectifiers that convert the AC input into DC current, as well as additional circuitry to control the current. The torch head assembly is connected to the PSU by a cable, and includes the electrodes that are used to make the welds. The gas cylinder contains the welding gas used in the process.

The welding torch used in arc welding is called a “rode”. Rodes are available as either straight or circular, and can be used for either linear or circular plasma arc welding systems. The rode is made from brass or copper, and has a tip that may have one or more electrodes depending on the type of system being used. Electrodes are made from tungsten because it has the highest melting point among all metals; this enables it to provide the greatest amount of heat during welding. In addition, its hardness allows the electrothermal erosion of the welded metals to take place during welding.

The control panel on plasma arc welding systems is used to adjust several different settings, including voltage and current for each electrode. It also includes a timer that can be set for a certain amount of time, as well as an overload protection circuit that cuts off power if there is too much voltage or current in the system. The cable reel on plasma arc welding equipment provides a means by which operators can move around while working with the system. The cable reel can be attached to the power supply unit or gas cylinder, depending on which one is being used by the operator at the time.

The electrodes used in plasma arc welding are capable of carrying high voltages; they must be handled with caution to prevent electric shock. Both linear and circular systems use two electrodes that operate simultaneously during welding. The electrode tips must be kept clean so that they provide a clear path for current flow and do not create any gaps between them.