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SpaceForm’s Evolution

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Presentation on theme: "SpaceForm’s Evolution"— Presentation transcript:

1 Super-MIG™ Combined Plasma-MIG Arc Technology and Equipment Manufactured by

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

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 Paton Welding Institute investigates the technology 1995 – PLT formed in Israel Emphasis on Plasma Laser PLT’s United States office started

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

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

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 Stability of the anode spot of the plasma arc is increased With SuperMig Magnetic Shield

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

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

9 Travel Speed Comparison
Welding Speed Per Inch Welding Metal Thickness

10 SuperMig Slow Motion Photography

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

12 Robotic Installation SuperMIG Torch Welding Power Supply Interface
Cleaning Station

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

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

15 System Component Description
Torch Cleaning Unit Step 1 Gas Shield Nozzle is removed and cleaned with spinning wire brush Fully Automatic via the robot program Four Step Process accomplished in 8 seconds Cleaning Frequency is based upon welding application Step 2 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

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

17 Contact Information Alain Piette, President SpaceForm Welding Solutions Inc. (USA) 1001 W. Thirteen Mile Road Madison Heights, MI (USA) Brian Finnigan, Manager Advanced Welding Technologies SpaceForm Welding Solutions Inc. (USA) 1001 W. Thirteen Mile Road Madison Heights, MI (USA)

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