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Plasma Cutter Versus Other Methods Of Welding And Cutting

Plasma Cutter Versus Other Methods Of Welding And Cutting. Brandon Hale ELEC 6750 Spring 2004. Questions. In which application is a plasma arc welder not used? How does one achieve laser like cuts to a plasma cutter?. Outline. Definition Of Terms History

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Plasma Cutter Versus Other Methods Of Welding And Cutting

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  1. Plasma Cutter Versus Other Methods Of Welding And Cutting Brandon Hale ELEC 6750 Spring 2004

  2. Questions • In which application is a plasma arc welder not used? • How does one achieve laser like cuts to a plasma cutter?

  3. Outline • Definition Of Terms • History • Companies Switching To Plasma Cutters • Plasma Cutting Variables • Adding Laser Like Cuts To A Plasma Cutter • Aerospace Applications

  4. Definition Of Terms • TIG – Tungsten Inert Gas • LBW – Laser Beam Welding • EBW – Electron Beam Weld • PAW – Plasma Arc Welder

  5. 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

  6. 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

  7. 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 Buyer’s Guide. Illinois, 2004

  8. Companies Switching To Plasma Cutters “let’s 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 Co Miller Electric Mfg. Co. Plasma Cutting Buyer’s Guide. Illinois, 2004

  9. 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.

  10. 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 Plasma Science, Vol. 30, p.1863-1871, 2002.

  11. Adding Laser Like Cuts To A Plasma Cutter 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.

  12. Adding Laser Like Cuts To A Plasma Cutter • Benefit: “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-Shamma’a 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.

  13. Aerospace Applications • TIG • Acceptable Welds For Copper • Excessive Porosity And Poor Fusion For Aluminum • 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,” IEEE Conference, Vol. 1, p.651-658, 2000.

  14. Aerospace Applications • 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,” IEEE Conference, Vol. 1, p.651-658, 2000.

  15. Conclusion • Plasma Cutters Have Led Companies In A Direction To Benefit From Costs Savings As Well As Quicker Project Completion Times • However, Plasma Cutting Yields Numerous Benefits, It Is Not Applicable For All Jobs

  16. Questions and Answers • In which application is a plasma arc welder not used? • Aerospace • How does one achieve laser like cuts to a plasma cutter? • Take a microwave continuous-wave magnetron for the power supply

  17. 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 Buyer’s 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,” 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.

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