Plasma Arc Cutting

Prepared by: RAGHAV SINGLA

Dr. Lotfi K. Gaafar 2003

Plasma Arc Cutting

PAC is a thermal material removal process that is primarily used for cutting thick sections of electrically conductive materials. Plasma can be defined as a superheated, electrically ionized gas.
Dr. Lotfi K. Gaafar 2003

PAC Process
PAC uses a high velocity jet of plasma (Temperatures range from 10,000 to 14,000 oC) to cut through the metal by melting it. The high gas flow rate facilitate the removal of molten metal through the kerf Stream pressures can reach up to 1.4 MPa.

Dr. Lotfi K. Gaafar 2003

Gases Used
Primary Gases: Gases that are used to create the plasma arc. Examples are nitrogen, argon, hydrogen, hydrogen, or mixture of them Secondary Gases or Water: Surrounds the electric arc to aid in confining it and removing the molten material.

Dr. Lotfi K. Gaafar 2003

System Components
Torch Power Supply Arc Starting Circuit

www.twi.co.uk/j32k/servlet/ getFile/jk51.html

Dr. Lotfi K. Gaafar 2003

System Components
A. The Torch:
The torch is the holder of the consumable electrode and nozzle. Responsible for forming the arc and maintain it in a vortex.
Groover 626

Dr. Lotfi K. Gaafar 2003

System Components
A. The Torch:
Types of Torches: Air Plasma Torch Oxygen-Injected Torch Water Injected Torch Dual Gas Torch

Dr. Lotfi K. Gaafar 2003

Types of Torches

Air Plasma (Benedict 337)

Water Injected (Benedict 340)

Dr. Lotfi K. Gaafar 2003

System Components
B. Power Supply:
Constant DC current source. Speed and cut thickness are determine by the amount of output current.

Dr. Lotfi K. Gaafar 2003

System Components
C. Arc Starting Circuit:
High frequency
generator circuit that produces a high AC Current. To start the arc, the AC current ionizes the cutting gas, which makes it conductive to allow the DC current to flow through it.
Dr. Lotfi K. Gaafar 2003

Types of Arcs
1. Transferred Arc: the generated arc is between the electrode and the work-piece.

Benedict 336

Dr. Lotfi K. Gaafar 2003

Types of Arcs
2. Non-Transferred Arc: the generated arc is between the electrode and the nozzle and heat is carried to the workpiece by the plasma gas.
Benedict 336

Dr. Lotfi K. Gaafar 2003

Advantages - Disadvantages
Cuts any metal. 5 to 10 times faster than oxy-fuel. 150 mm thickness ability. Easy to automate.
Large heat affected zone. Rough Surfaces Difficult to produce sharp corners. Smoke and noise. Burr often results.

Dr. Lotfi K. Gaafar 2003

Applications
Pipe industry preparing pipe edges for welding.

industries for shape cutting

Cpam.engr.wesc.edu

Dr. Lotfi K. Gaafar 2003

Other Plasma Uses

Plasma Arc Welding (PAW)- plasma arc is produced and aimed at the weld area to weld. Applications- Used for butt and lap joints because of higher energy concentrations and better arc stability.

Dr. Lotfi K. Gaafar 2003

Safety Precautions
Machine the heat affected zone (0.75-5 mm). Regulate gas pressure (approx. 1-1.4 MPa). Maintain constant distance between torch and work piece. High labor safety (i.e. goggles, gloves, etc). Proper training for operators. Protection against glare, spatter and noise from the plasma.
Dr. Lotfi K. Gaafar 2003