Every year, the pace of development of industry is increasing. This leads to the introduction of new technologies and methods for manufacturing certain products. At the same time, innovations should be not only more effective than obsolete methods, but also not inferior in terms of economic feasibility and safety of work. Let's talk about what is plasma welding. It appeared relatively recently, but is already very actively used in many industries.
About Plasma Welding
This joining method is used for metal pipes, stainless steel and some other materials. The essence of the method is local melting when the plasma flow is directed to the desired area. Plasma is an ionized gas stream that contains many charged particles that actively conduct electric current. During heating, gas ionization occurs, which is achieved by using a high-speed arc exiting directly from the plasma torch. Naturally, with increasing gas temperature, the degree of ionization increases. The temperature amplitude of the arc is not less than 5 and not higher than 30 thousand degrees Celsius. Of course, today plasma welding is used everywhere, but the equipment, in particular the plasma torch, is very expensive. In this way, you can connect parts without cutting edges, which is very convenient.
Principle of operation
Plasma welding is possible only if it is possible to obtain a plasma from a conventional arc. This is usually achieved by compression and using a system of forced supply of special gas into the arc. Argon with a small amount of helium or hydrogen is used as a plasma-forming gas. It is extremely important to create a protective sheath around the electrode; the same argon is best suited for these purposes. By the way, the electrodes are made of tungsten activated by thorium or yttrium. It should be noted that the plasma torch walls are very hot due to high pressure, so they need to be constantly cooled. From the foregoing, it can be concluded that plasma welding is notable for its high temperature in combination with a small arc diameter. The last parameter allows you to increase the pressure on the metal several times. In addition, the process is supported with a small current of 0.2-3.0 amperes.
DIY plasma welding
At first, this type of welding was not used among home craftsmen, as it required high qualifications. Today the situation has not changed dramatically. However, there are welding machines that are suitable for use in a domestic environment. The technology in this case is quite simple. You will need to acquire a special welding machine, electrodes and filler wire.
Before starting work, the electrode is sharpened to a conical shape with an angle of not more than 30 degrees. It is imperative that the electrode is installed correctly. The main thing is to monitor the coincidence of the axis of the electrode with the axis of the gas nozzles. The weld joint is processed in the same way as in argon welding. The edges are cleaned and degreased, only after this you can begin to perform work. By the way, pay attention to the absence of gaps of more than 1.5 mm. The tack sections need to be additionally cleaned up and making sure that the tack points and welding seam are similar in quality.
We continue to work
Do-it-yourself plasma welding is performed at constant current, the value of which should not go beyond the recommended range. In addition, shielding gas is supplied 5-20 seconds before the start of welding, which turns off approximately 10-15 seconds after the arc breaks. During operation, the plasma torch should be at a distance of not more than 1 cm from the product, and it is advisable not to break the arc until the end of the seam. When welding, metal overheating must not be allowed. Upon reaching a critical point, plasma welding is suspended. The metal is cooled by compressed air, and only after this work resumes. Please note that the burner must move smoothly and evenly, as on an automatic device. In this case, you can count on a really high-quality and reliable seam.
Gorynych plasma welding: price and features
The multifunctional welding machine "Gorynych" is one of the most famous among domestic machines. We can say that this is really a quality product, thanks to which you can independently carry out welding work. It is worth noting that the Gorynychy lineup is different in power. There are models for 8, 10 and 12 Amps. The first option is perfect for domestic needs, the middle one has an excellent price / performance ratio, and the most powerful Gorynych is used only by professionals. So, a model with 8 Amps will cost 29 thousand, 10 A - 30 thousand, and 12 A - 33 000 rubles. In principle, Gorynych plasma welding, the price of which is lower than that of its foreign counterparts, is very popular in Russia, Ukraine, Belarus and other countries.
Plasma Welder
If it was very difficult to find a suitable model before, today there are no problems with this. As a rule, a plasma welding machine can be found in any specialized store. You will be pleasantly surprised by the large selection of units offered. But all of them are much more expensive than electric welding and inverters. Plasma apparatus against the background of other options looks very profitable. Firstly, the speed of work performed is many times higher, and secondly, there is practically no waste left. For plasma welding, electricity and compressed air are required, and if there is a special compressor, only a network connection is needed. The torch nozzle and electrode are subject to periodic replacement. In addition, the plasmatron should be refueled regularly. For this, special cylinders are used. Interestingly, plasma cutting and welding are considered the safest. Nevertheless, it is advisable to carry out the work outdoors or in a well-ventilated area.
About medium current welding
We already know a little about what plasma welding is. The price of equipment, as you see, depends on its capacity. But it is worth paying attention to the fact that there are several types of welding. One of them is work on an average current (50-150 amperes). Such welding can be compared with argon welding, but it is considered somewhat more efficient, since the arc power is higher and the heating area is limited. This option, compared with the traditional arc, allows you to increase the depth of penetration of the processed metal and improve the transfer of heat deep into the layers. In principle, this is due not only to energy performance, but also to high pressure on the weld pool. Medium current welding is carried out using filler wire. Today it is a very popular and effective solution. If you are going to work at home, this kind of plasma welding is suitable for you. The price of equipment will not differ, as there is provided the possibility of adjustment.
High current welding
In this case, the work proceeds under a current of more than 150 amperes. This is necessary to obtain a greater effect on the metal. In fact, welding at 150 A is similar to welding at the same temperature with a non-consumable electrode. A distinctive feature of this solution is that during the execution of work a through hole is formed in the bathroom, which ensures complete penetration of the treated surface. But here it is extremely important to observe the technology, since with a careless attitude, you can easily get burns. In addition, other important parameters must be observed: cooling the plasma torch and its storage conditions, periodic replacement of the burner nozzle, refueling, and much more. In principle, instructions are written for a reason, and the requirements must be followed. Typically, a high-current plasma welding and cutting machine is required for joining alloyed and low-carbon steels, copper, titanium, and other materials.
Reviews of professionals and beginners
So we reviewed this topic with you. As you can see, plasma welding is quite interesting and effective. Numerous responses have been compiled about this. Professional welders say that where argon welding fails, only plasma is suitable. Beginners note that this type of welded joint production is good not only for its speed, but also for the high quality of the weld.
In addition, the performance of all work in compliance with the operating rules is completely safe. If you are going to do welding at home, the Gorynych apparatus is suitable. This equipment from a domestic manufacturer is considered very high quality and at the same time has a very affordable cost. Of course, the price compared to welding inverters may seem sky-high, but you have to pay for quality. By the way, plasma welding “Gorynych” makes it possible to carry out all installation work quite simply. But first you need to carefully read the instructions and prepare for the first use. Your first experience will seem very unusual, but over time you will see that the quality of the seam is at a professional level.