A New Hybrid Plasma-GMA Welding Process Features Many
Coaxial application with wire feed through plasma torch. 1984- First plasma MIG system developed for welding zinc coated steels. Low power and slow travel ...
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1. Super-MIG™ Combined Plasma-MIG Arc Technology and Equipment Manufactured by 1

2.SpaceForm’s Evolution Delphi creates Weldmation Creates SpaceForm Inc. Welding Solutions Inc. WSI) SpaceForm has worldwide rights WSI Licenses to the DRW SuperMig® from technology PLT SpaceForm and Welding Solutions merge to form SpaceForm Welding Solutions Inc. to commercialize DRW and SuperMig Technologies 2

3.Process History 1969 - Philips Research Laboratories – Coaxial application with wire feed through plasma torch 1984- First plasma MIG system developed for welding zinc coated steels – Low power and slow travel speed application – Attempts at higher amperage levels and speeds resulted in process instability 1990 - Paton Welding Institute investigates the technology 1995 – PLT formed in Israel Emphasis on Plasma Laser 2001 - PLT’s United States office started 3

4.Super-MIG™ SuperMig Hybrid Plasma/MIG Welding System Integration with all standard robotic MIG welding systems Consists of Three Components: Interface, Torch, and Cleaning Station Utilizes standard MIG power sources: Lincoln, Miller, Fronius, Panasonic, OTC, etc… Capable of operating in multiple welding process modes: Plasma, Plasma/MIG 4

5.Process Basics The Plasma arc is started • Keyhole may be established Travel Direction MIG wire feed started, establishing the MIG arc. 5

6.Process Interactions DCEN DCEP Magnetic field interaction between the two arcs wants to force them apart Without SuperMig Magnetic Shield DCEN DCEP Magnetic Shield With the introduction of an additional magnetic field the arcs can be brought together. This field is adjustable With SuperMig Magnetic Shield Stability of the anode spot of the plasma arc is increased 6

7.Process Variables Preheating and depression of metal surface allows for deeper penetration without a full keyhole Heat from plasma torch adds to melting of MIG wire Higher deposition rates More consistent arc lengths Reduced spatter Plasma power levels High amperage - Penetration Low amperage – Part cleaning / Coating removal Magnetic shield levels High levels – Narrows arcs / Increased penetration Low level – Wider arcs / Preheating 7

8.HAZ Comparison MIG SuperMIG 1400° 1400° 1400° 1400° 1200° 1200° 1200° 1200° 1000° 1000° 1000° 1000° 800° 800° 800° 800° 600° 600° 600° 600° Travel speed - 90 in/min Travel speed - 50 in/min Travel speeds chosen to obtain equal penetration Temperatures (oC) 8

9.Travel Speed Comparison Welding Speed Per Inch Welding Metal Thickness 9

10.SuperMig Slow Motion Photography 10

11.Heavy Section Development Travel Plasma Mig Material Speed Current Current (ipm) (A) (A) 300 series Stainless 16.6 340 536 Steel 11

12.Robotic Installation SuperMIG Torch Welding Interface Power Supply Cleaning Station 12

13.System Component Description Interface • Compatible with all standard robot controllers • Includes an integrated Unitronics PLC • Capable of storing multiple welding programs • Gas flow monitor allows gas mixture adjustment • Plasma power source • Pump and reservoir for the torch cooling system 13

14.System Component Description Torch – Hard Bodied Torch – Water Cooled – Electrically Isolated – Wire diameters PlasmaandMIG • .035”,.045”, .052” Torch amps amps STD 200 350 HCC 200 500 HD 350 650 • Under development - Aluminum - Hardfacing 1

15.System Component Description Torch Cleaning Unit Step 1 • Fully Automatic via the robot Gas Shield Nozzle is program removed and cleaned • Four Step Process accomplished in with spinning wire 8 seconds brush • Cleaning Frequency is based upon Step 2 welding application Torch moves to forward position where spinning blades clean MIG and Plasma tips Step 3 Torch moves back to first position where Gas Shielding Nozzle is reattached Step 4 Torch Nozzle is sprayed with a small amount of anti-spatter liquid 1

16.Benefits compared to Conventional MIG • Travel Speed – Increased Welding Speed (2 times over std. MIG) • Quality – Weld Penetration – Removal of coatings or contaminates – Narrow Heat Affected Zone (HAZ) • Cost – Reduced Edge Preparation – Part Cleaning – Increased Production – Reduced Capital Equipment/Tooling 16

17.Contact Information Alain Piette, President SpaceForm Welding Solutions Inc. 248-931-3886 (USA) 1001 W. Thirteen Mile Road Madison Heights, MI 48071 (USA) Email alain.piette@spaceformtech.com www.spaceformtech.com Brian Finnigan, Manager Advanced Welding Technologies SpaceForm Welding Solutions Inc. 937-369-8194 (USA) 1001 W. Thirteen Mile Road Madison Heights, MI 48071 (USA) Email b.finnigan@spaceformtech.com www.spaceformtech.com 17