PLASMA TECHNOLOGY IN METALLURGY & METALWORKING

Presented By

Mr. Arun KumarMANAGING DIRECTOR

Technocrats Plasma Systems Pvt Ltd

WHAT IS PLASMAPlasma is popularly known as 4th state of matter, other three being Solid, Liquid & Gas. 

After the gas is heated or external energy is applied to the gas, it gets ionized and plasma is formed. Plasma conducts electricity. It’s a very hot substance. Plasma exits in nature as well.  Plasma is generated in a specially designed gun called plasma torch using electrical power for various engineering applications including metal cutting. The process is known as Plasma cutting. 

Plasma cutting is becoming increasingly popular these days due to its advantage over conventional method of cutting metals. Plasma can cut all conducting metals such as SS, MS, AL, COPPER, BRASS, INCONEL and MONEL etc.

APPLICATION OF PLASMA IN METALLURGY AND METAL WORKING

Application of Plasma in Metallurgy & Metal

working

Melting & Steel

Making

Surface Modification & Coating

Welding Cutting & Gouging

Steel Making

Plasma Furnaces

Advantages of Plasma FurnacesThe plasma arc furnace is a device to melt a substance by low-temperature plasma flow, typically created by an electric arc heater (plasmatron). The main field of application of the plasma furnace is electrometallurgy. The main advantages of a plasma furnace are:• high stability of the working process and an opportunity of

continuous temperature adjustment by changing the plasmatron electric conditions

• the opportunity of operation in practically any desired atmosphere

• high degree adoption of alloying additions

• a decrease of the impurities content and, consequently, an opportunity of smelting low-carbon steels and alloys

• an opportunity of smelting the nitrided steels by usage of gaseous nitrogen

• a relatively small pollution of ambient air

Various direct current (DC) and alternating current (AC) plasmatrons are used in plasma furnaces. In large-scale plasma furnaces, several plasmatrons are used to provide more homogeneous heating

Surface Modification & Coating by PlasmaLow Pressure Plasma Technology is used for-

1. ADHESION PROMOTION2. CLEANING3. HYDROPHILIC PROPERTIES4. OLEOPHOBICITY AND HYDROPHOBICITY5. LOW-FRICTION COATING6. BARRIER COATINGS7. STERILIZATION

Plasma SprayingThermal SprayThis is the method of applying materials onto a prepared base material by heating particles in the stream of a heat source, creating a semi-molten state. Particles are then propelled by high velocity onto a prepared substrate where they adhere to the base surface via a mechanical bond.

Particles continue to build until a specified thickness is attained. This technique is considered the "cold method of welding", whereas high temperatures can be achieved in the heated pocket, while the temperature of the part itself usually remains under 200°F.

Typical physical specifications of coatings:• Maximum hardness of 72 Rc hardness (Tungsten

Carbides)• Surface texture as sprayed is rough, from 150 to 1000+ Ra• Thickness range from .002 to .150• Bond strength range: 2500 -15000 PSI

Advantages• No degrading of parts due to heat warping and distortion• No degrading of part metallurgy or integrity• Surfaces are enhanced to provide improved performance

One of the Core Coating Application Techniques is-

Plasma Spray: In this process we use various gasses that are ignited by an electric arc. Temperatures can rise up to 30,000° F while the part temperature remains at less than 200°F. Particle velocity is greater than in the other four systems. One of the benefits of using this system is the high heat, which can process materials with high melting points (including ceramics).

Advantages of Plasma Spraying• A wide range of coating materials to meet many different needs,

with virtually all materials available in a suitable powder form.• Higher quality coatings than other more conventional thermal

processes such as flame or electrical arc spraying.• Many types of substrate material, including metals, ceramics,

plastics, glass, and composite materials can be coated using plasma spraying.

• The high temperature of a plasma jet makes it particularly suitable for spraying coatings of refractory metals and ceramics, including ZrO2, B4C and tungsten.

• A broader powder particle size range can be used, typically 5-100µm, compared with HVOF spraying.

• Plasma spraying is a well-established coating process that is widely available and well understood.

USE OF PLASMA IN FORGING

Forging is a metalworking process where a work piece is shaped by compressive forces using various dies and tools.During forging, high mechanical, chemical and thermal cyclic loads acting simultaneously which leads to a failure of the form giving tool components after a short tool life.

Accounting for about 70% of all causes‘Plasma Nitriding’ is the best surface hardening treatment. It is done through Plasma Nitriding Suite consisting of Vacuum Chamber; Pulsed Plasma Generator; System Controller; Vacuum System and Gas Supply System.

USE OF PLASMA IN ROLLINGRolling is a direct compression deformation process, which reduces the thickness or changes the cross section of a long work piece.Use of Plasma Cutting Machines is very popular in Rolling mills across Europe. Plasma cutting machines are used to cut the foils, sheets or plates at a desired length

USE OF PLASMA IN TUBE/SHEET FORMING

• Plasma coating is extensively used for hardening the surfaces of sheet or tube

• Plasma cutting machines are used to cut sheets and billets at desired length

• Plasma cutting machines along with pipe cutting attachments are used to cut tubes and pipes at desired length

• Plasma Cutting machines often replaces shearing machines in the process of sheet forming

Automatic Billet Cutting with Plasma

USE OF PLASMA IN MACHINING

-Plasma arc can be used for Removing material from the surface of rotating cylindrical jobs.

-Also, Plasma arc can be used for softening of metal by placing the arc before cutting tool in Sophisticated Lathe machines to make the metal soft, which increases the metal removal rate.

PLASMA CUTTINGMYTH REALITY

Plasma Cutting is only for SS Plasma can cut any electro conductive material like SS, MS, Al,

Cu, Zn, Ag, Sn, etcPlasma cutting is a costly process Plasma cutting is up to 80%

cheaper than gas cutting

Plasma Cutting needs high safety measures

Plasma is safer than gas as it does not use fire or cylinders

Plasma Cutting needs skilled workers

It is easier to cut in plasma as the process is fast & hence requires less time for concentrating on the

job

PLASMA CUTTING PROCESS

Types of Plasma Cutting Machines

Manual Power Source

Semi-Mechanized Cutting Machine

Manual Torches

Manual Plasma Cutting Machines

MECHANIZED CUTTING MACHINE

CNC CUTTING MACHINE

Sample Cut Pieces

Sample Cut Pieces

CNC PIPE PLASMA/GAS PROFILE CUTTING MACHINE

Pipe Profile Cutting with Plasma

Sample Cut Samples

COST BENEFIT OF PLASMA CUTTING OVER CONVENTIONAL GAS CUTTING

Cost of Mild Steel (MS) cutting with Gas“As per empirical formula, 6 Cylinder of Oxygen & 1

Cylinder of LPG can cut 1200 mm-Meter”Plate Thickness

Length Cut Cost of LPG(@ Rs. 2000/Cylinder)

Cost of Oxygen(@ Rs. 200/Cylinder)

Cost of Consumable

Labor Cost (@Rs. 50/Hr & Cutting speed @200 mm-Meter/Hour)

Total Cost Cost (Rs./Meter)

5 240 2000 1200 80 300 3580 14.92

10 120 2000 1200 80 300 3580 29.83

15 80 2000 1200 80 300 3580 44.75

20 60 2000 1200 80 300 3580 60

Cost of Mild Steel (MS) cutting with CNC Plasma Profile Cutting Machine

Plate Thickness

Length Cut per Hour

Electricity Cost (@18.5 KW/Hr & Rs. 8/KW)

Consumable Cost

Labor Cost (Operator cost @ Rs. 75/Hour)

Total Cost Cost (Rs./Meter)

5 105 (@1.75m/min)

148 400 (2 Sets) 75 623 5.95

10 90 (@1.5m/min)

148 600 (3 Sets) 75 823 9.15

15 72 (@1.2 m/min)

148 800 (4 Sets) 75 1023 14.2

20 56 (@0.93 m/min)

148 800 (4 Sets) 75 1023 18.3

Savings by CNC Air Plasma Cutting over Gas Cutting

Plate Thickness Cutting Cost with Gas Cutting (Rs. Meter)

Cutting Cost with Plasma Cutting (Rs./Meter)

Savings (Rs./Meter)

5 14.92 5.95 8.97

10 29.83 9.15 20.68

15 44.75 14.20 30.55

20 60 18.30 41.70

USE OF PLASMA IN WELDING1. Micro Plasma Welding-used for very thin foil welding of 0.01 mm to 1 mm approx

2. Plasma Welding-used for key hole welding

3. Plasma Transferred Arc-used for repairing welding, deposition, etc.

ANY QUESTIONS ???

Registered Office304 & 310, Tapo Commercial Centre,Ram Mandir Road, Goregaon West,

Opposite MovieStar Multiplex, Mumbai - 400 104, India.

Phone No.: +91-22-26763513 / 14

Corporate Office & Works (Factory)Nirav No. 2, Gaon Devi Industrial Complex

Near Gaon Devi Temple, Sativali, Vasai,Palghar– 401 202.Maharashtra, India

Phone No.: +91-250-3262624. (Reception)                   +91-250-6453954. (Reception)                   +91-250-3248074. (Marketing)

For any enquiries you can call us on 09320033114 or you can mail us on marketing@technocratplasma.com

THANK YOU