Introduction
Welding is the process of connecting pieces of a material through heat and pressure. It is a vital process for any structure that needs to be secured and consists of two distinct parts: the filler material and the heat source. Welding has become an important process in modern construction, with manual and robotic welding systems being used constantly to ensure the safety and quality of welding. In manual welding, the weld is created through heat and pressure provided by an electrical arc or a flame source. In robotic welding, a robotic system is used to weld a material in a predetermined path, and robotic systems are now being used increasingly as an alternative to manual welding in many fields.
However, manual welding has some major limitations, mainly due to heat transfer and oxidation. If the welding temperature is too high, the material can reach its melting point, resulting in excessive heat loss and the oxidation of the material. This can lead to poor weld quality, as the oxidation weakens the material and prevents it from holding together properly. Additionally, manual welding requires a high level of skill and experience, and the process is inherently dangerous as it uses high levels of heat and electricity.
To improve the safety, accuracy and repeatability of welding, an alternative form of welding is becoming increasingly popular: Plasma Arc Welding (PAW). Plasma arc welding is a process of using a plasma arc between an electrode and the workpiece to melt the filler material and form a strong weld. The plasma arc is created by the current passing through the space between the electrode and workpiece, creating a hot, ionized gas which then melts the filler material, forming the weld.
Unlike manual welding, Plasma Arc Welding does not use high temperatures, instead relying on a localised arc of a few inches in size. This greatly reduces the risk of oxidation and heat loss in the weld, as well as allowing for more precise welding on smaller parts. Additionally, the process is much faster than manual welding and allows for greater repeatability as the settings do not need to be adjusted for each weld. Plasma arc welding also requires less skill to use and can be used in a wide range of applications, from automotive components to industrial equipment.
Conclusion
Overall, plasma arc welding is becoming an increasingly popular alternative to manual welding due to its superior speed, accuracy and repeatability. With a range of settings, it can be used in a variety of applications, and its ability to create welds with less waste and less heat loss makes it an ideal choice for modern industry.
