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

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Presentation on theme: "™ Combined Plasma-MIG Arc Technology and Equipment Manufactured by Super-MIG™ Combined Plasma-MIG Arc Technology and Equipment Manufactured by 1."— Presentation transcript:

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

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

3 Process History Philips Research Laboratories –Coaxial application with wire feed through plasma torch 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 3

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

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

6 6 DCEP DCEN Magnetic field interaction between the two arcs wants to force them apart 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 DCEP DCEN Process Interactions With SuperMig Magnetic Shield Without SuperMig Magnetic Shield 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 7

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

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

10 SuperMig Slow Motion Photography 10

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

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

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

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

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

16 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 Benefits compared to Conventional MIG 16

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


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