Superconducting Broadband Plasma Arc Welding Technology (Part one)
Introduction
Superconducting Broadband Plasma Arc Welding (BBPAW) is an advanced technology capable of welding specialty components and materials that cannot be joined using conventional processes. This technology performs welding with a single sheet, multi-pass process with superior weld integrity compared to existing methods. The use of Broadband Plasma Arc Welding (BBPAW) provides a cost-effective, reliable and consistent weld, which is highly homogenous and suitable for a wide variety of important components, including special alloys, clad materials, and cast alloy steels.
BBPAW technology is a specialized welding technique developed over years by plasma processing experts and other field specialists. Unlike conventional welding techniques, BBPAW requires high temperatures, controlled plasma arc concentrations, and optimized deposition of filler material, to achieve perfect welds. This advanced technology has high automation potential and is capable of welding virtually any material, including stainless steels, aluminum alloys, carbon steel and other high-grade materials. BBPAW is used in high precision, critical applications and is popularly used in aerospace, military and other heavy industry applications.
Objectives
The main benefits of implementing BBPAW are improved productivity, stability, consistency and quality of welds, with minimal material wastage. Additionally, the use of this advanced technology reduces the risk of welding defects and minimizes the need for welding rework.
The objectives of BBPAW are to:
• Reduce overall welding costs by eliminating the need for secondary or finishing operations and providing a cost-effective solution to high-strength joining processes
• Minimize welding heat input and preheat requirements for materials, leading to improved weld integrity and superior joint quality
• Increase process stability and welding consistency by ensuring perfect welds with no voids or cracks
• Enable a single sheet, multi-pass process for welding thick and complex components, which traditional welding processes cannot achieve
• Enhance productivity and reduce weld cycle time by allowing simultaneous deposition of multiple layers in a single pass
• Streamline welding scheduling and keeping scrap and spool times to a minimum
Process Description
BBPAW is a manner of welding that utilizes a superconducting plasma arc at the interface between two materials. A unique combination of current and voltage controls to the two working surfaces creates a stable plasma arc at the interface that is capable of efficient heat regeneration, creating a superior weld. The process can be used for a variety of materials, including stainless steel, aluminum alloys and carbon steel.
The process begins with a surface preparation of the materials to be joined, which helps enhance the quality of the weld. The parts are aligned and clamped in position, and then the gap is filled with a flux-cored filler wire. The wire is then melted and crystallized through the high-temperature plasma arc. Once the weld is complete, the surrounding area is inspected for visual defects, checked for surface roughness and then finished as required.
Advantages
BBPAW has become increasingly popular due to its advantages over traditional welding processes. These advantages include:
• Higher quality welding: BBPAW produces more consistent, homogenous, and high-integrity welds, with smaller final heat affected zones and less chance of cracking
• Improved productivity: the process combines the flux-cored welding process with plasma arc cutting technique, which reduces the need for secondary operations
• Lower downtime: BBPAW is capable of very high automated welding speeds and consistency, reducing downtime and operator fatigue
• Precision: BBPAW is capable of reliably and accurately welding complex components and materials, which are difficult to achieve with conventional welding techniques
• Reduced warping: BBPAW uses minimal preheat, allowing for single sheet and multi-pass welding of thick components, with negligible warpage or distortion
Conclusion
BBPAW is a highly specialized welding technique, offering improved weld integrity, quality and reliability over existing methods. This advanced technology is suitable for a wide range of materials and applications, due to its reliable and accurate precision as well as its high-automation potential. BBPAW also minimizes downtimes, scrap and spool times, offering improved overall productivity and cost savings in the long-term.
