Plasma Welding: Everything You Need to Know | HARtech

Plasma welding, or plasma arc welding (PAW), is used in many industrial sectors. A versatile and high-performance welding technique, the plasma welding process can be used to produce top-quality welds.

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HARtech’s industrial welding professionals take a closer look at plasma welding, explaining how it works, what it’s used for and the benefits it offers. Learn how this innovative welding technique can help your business.

How plasma welding works

Plasma welding is an advanced welding technique that uses a high-temperature, ionized gas known as plasma to create and maintain an electric arc between a welding electrode and a workpiece. The intense heat generated by the plasma arc melts the base metal and filler material (if used), resulting in a strong and precise weld.

In the plasma welding process, an inert gas (e.g., argon) creates a protective environment around the arc and weld zone, which prevents contamination of the weld by oxygen from the air and guarantees a high-quality weld.

Common uses for plasma welding

Plasma welding is widely used in many industrial sectors. Applications include the automotive, aerospace, shipbuilding, industrial machinery design, and petrochemical industries. Plasma welding is used to build pipes, tanks, metal structures, engine parts, cutting tools, and more.

Since it can be used on different types of material, plasma welding is a highly sought-after welding technique. Plasma welding helps improve the productivity, quality, and efficiency of various manufacturing and construction processes.

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Stages of the plasma welding process

To perform efficient, high-quality plasma arc welding, a complete understanding of the plasma welding process is essential. Read on to learn more.

Preparing parts for welding

Before beginning the plasma welding process, it is essential to prepare all parts. This includes cleaning surfaces to remove contaminants such as rust, grease, or paint residues. Chamfering or deburring may also be necessary to ensure fusion and metal adhesion are successful and you obtain a high-quality weld.

Setting up plasma welding equipment

It's time to set up the plasma welding equipment. This involves mounting the electrode, connecting the power supply and shielding gas cables, and checking all safety parameters. Plasma welding equipment generally includes a power source, a plasma welding torch, and a cooling system.

Plasma welding parameters and settings

There’s one more step before you start welding. Adjust settings and parameters according to the material you are welding, the thickness of the parts, and any welding specifications. You will need to verify electric current intensity, wire feed speed, shielding gas pressure, the distance between the electrode and workpiece, and other variables specific to your plasma welding project. A professional welder-assembler can guarantee the precision of settings and parameters for optimum metal fusion and penetration.

Creating the weld

The operator directs the plasma welding torch along the welding area, which generates an electric arc and intense plasma. The thermal energy of the plasma melts the base metals and filler material, forming a solid, homogeneous weld. The operator must use proper welding technique, control feed speed, and maintain a constant distance between the torch and workpiece to achieve optimum results.

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