Branden Hale- Plasma Cutting.ppt

7/27/2019 Branden Hale- Plasma Cutting.ppt

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Plasma Cutter Versus OtherMethods Of Welding And Cutting

Brandon Hale

ELEC 6750Spring 2004


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Questions

In which application is a plasma arcwelder not used?

How does one achieve laser like cutsto a plasma cutter?


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Outline

Definition Of Terms

History

Companies Switching To Plasma Cutters

Plasma Cutting Variables

Adding Laser Like Cuts To A Plasma Cutter

Aerospace Applications


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Definition Of Terms

TIG Tungsten Inert Gas

LBW Laser Beam Welding

EBW Electron Beam Weld

PAW Plasma Arc Welder


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History

1950 TIG Welding

1957 Conventional Plasma Cutting

1962 Dual flow Plasma Arc

1963 Air Plasma Cutting

1968 Water Shield Plasma Cutting 1972 Water Muffler For Plasma Cutting

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


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History

1977 Underwater Cutting

1980 Low Amp Plasma Cutting

1983 Oxygen Plasma Cutting

1985 Oxygen Injected Plasma Cutting

1990 High Density Plasma Cutting

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


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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


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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.


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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 Pla smaScience, Vol. 30, p.1863-1871, 2002.


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A Plasma Cutter



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A Plasma Cutter Benefit:

The cost savings means that the

microwave plasma torch is a better choicefor material cutting and welding whenprecision is not critical.

- Ahmed I. Al-Shammaa



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TIG

Acceptable Welds For Copper

Excessive Porosity And Poor Fusion ForAluminum

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,IEEEConference, Vol. 1, p.651-658, 2000.


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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,IEEEConference, Vol. 1, p.651-658, 2000.


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Conclusion

Plasma Cutters Have Led CompaniesIn A Direction To Benefit From Costs

Savings As Well As Quicker ProjectCompletion Times

However, Plasma Cutting Yields

Numerous Benefits, It Is NotApplicable For All Jobs


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Questions and Answers

In which application is a plasma arcwelder not used?

Aerospace

How does one achieve laser like cutsto a plasma cutter?

Take a microwave continuous-wavemagnetron for the power supply


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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, IEEETrans. 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, IEEEConference, Vol. 1, p.651-658, 2000.

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Branden Hale- Plasma Cutting.ppt