Plasma Cutter Versus Other Methods Of Welding And CuttingBrandon HaleELEC 6750Spring 2004

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

OutlineDefinition Of TermsHistoryCompanies Switching To Plasma CuttersPlasma Cutting VariablesAdding Laser Like Cuts To A Plasma Cutter Aerospace Applications

Definition Of TermsTIG Tungsten Inert GasLBW Laser Beam WeldingEBW Electron Beam WeldPAW Plasma Arc Welder

History1950 TIG Welding1957 Conventional Plasma Cutting1962 Dual flow Plasma Arc1963 Air Plasma Cutting1968 Water Shield Plasma Cutting1972 Water Muffler For Plasma CuttingBohlen, K. Ed, et al. Hypertherm's plasma cutting history. http://www.hypertherm.com/technology/plasma_history.html

History1977 Underwater Cutting1980 Low Amp Plasma Cutting1983 Oxygen Plasma Cutting1985 Oxygen Injected Plasma Cutting1990 High Density Plasma CuttingBohlen, K. Ed, et al. Hypertherm's plasma cutting history. http://www.hypertherm.com/technology/plasma_history.html

Companies Switching To Plasma CuttersBenefits of Plasma Cutting:Faster Cutting SpeedNo Pre-heat CycleSmaller Cut WidthSmaller Heat Affected ZonePortable UnitCostMiller Electric Mfg. Co. Plasma Cutting Buyers Guide. Illinois, 2004

Companies Switching To Plasma Cutterslets 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 CoMiller Electric Mfg. Co. Plasma Cutting Buyers Guide. Illinois, 2004

Plasma Cutting VariablesVoltageNozzleAir 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 CutterOne 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 CutterA. 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 CutterBenefit: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-ShammaaA. 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 ApplicationsTIG Acceptable Welds For CopperExcessive Porosity And Poor Fusion For AluminumEBW No Fusion Between Aluminum Weld ElementsK. 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 ApplicationsPAW Best Fusion On AluminumInconsistent WeldsLBW Best Weld For Aerospace ApplicationsRequires Oxidation of AluminumNo Preparation For CopperK. 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.

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

Questions and AnswersIn which application is a plasma arc welder not used?AerospaceHow does one achieve laser like cuts to a plasma cutter?Take a microwave continuous-wave magnetron for the power supply

ReferencesBohlen, K. Ed, et al. Hypertherm's plasma cutting history. http://www.hypertherm.com/technology/plasma_history.htmlMiller Electric Mfg. Co. Plasma Cutting Buyers Guide. Illinois, 2004A. 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.