Plasma transferred arc coating machine | PTA hardfacing for lead screw

Plasma transferred arc coating machine is automated specialized in the production of lead screws, applicable to screws, spiral parts, all kinds of shafts, and extended shaft OD coating plasma surfacing reinforced.

Main components:

The machine adopts imported linear guide.

It is driven by precision worm gearboxes and stepper motor drive.

The whole machine has a small transmission gap, high rigidity, smooth and reliable operation, and easy integration.

Applications:

For general shaft parts, pipe parts of the outer and inner hole surfacing. It can also be used for the surface welding and repair of screws and other components.

Plasma transferred arc coating

Brief description:

The plasma arc is used as a heat source to rapidly apply the high temperature generated by the plasma arc to heat the alloy powder and the substrate surface quickly. And together, they melt, mix, diffuse and solidify. After the plasma beam leaves the self-excited cooling, a high-performance alloy layer is formed, thus achieving the strengthening and hardening of the part surface surfacing process. As the plasma arc has a high arc temperature, significant heat transfer rate, excellent stability, melt depth controllability, through the adjustment of the relevant welding parameters. The thickness, width, and hardness of the surfacing layer can be freely adjusted within a specific range. Plasma powder surfacing after the formation of a fusion between the base material and the surfacing material interface, the combination of high strength, surfacing layer of dense tissue, corrosion, and Good wear resistance; reduced dilution of the base material and the cladding material, less change in material properties. The use of powders as surfacing materials can improve alloy design’s selectivity, especially the ability to smoothly surfacing refractory materials, improving the wear resistance, high temperature, and corrosion resistance of the workpiece.

PTA hardfacing machine for lead screw

Function:

The current plasma surfacing machine on the market only has a single function (powder cladding), and the workpiece is surfacing only. The WALDUN plasma welding machine is equipped with two functions: powder cladding and TIG welding, which is challenging due to the limitation of surface cladding and inner hole cladding. It offers more options for repairing some small areas. The 65mm gun has made an indelible contribution to the bore surfacing industry as opposed to bore surfacing.

Advantages:

Functional aspects.

Weld to guide the dimensional arc, high-power argon arc welding to guide the main arc. Thus making the host bulky and challenging to carry, thus making the machine only suitable for one-way work, should not go out to work. The WALDUN plasma welding machine is to overcome the reasons that the voltage of the arc is too high, and the micro-arc is unstable. The above problem, using a simple plasma power system, is small and light in weight suitable for working in any situation.

Plasma gun for welding.

Most of the current plasma welding guns on the market are external powder feeding systems, the gun handle is also made of everyday materials, so that in The use of the process is prone to blocked powder or leakage phenomenon, seriously affecting the standard production needs and the user’s life safety. WALDUN plasma welding torch adopts a built-in powder feeding system. The torch handle is made of polyethylene insulation material, which overcomes the problem of powder plugging and leakage in the process of using. The welding torch does not carry enough current to reach the full load of the machine. The carrying current of the welding gun is not enough to match the machine to achieve full capacity.

For the powder feeder.

The current plasma welding machine on the market are scraper type powder feed, this way of sending powder for a long time easy to carry powder unevenly. WALDUN plasma welding machine adopts the current impeller type powder feed, which can be used for the welding of the plasma surface. Accurate control of the size and speed of the powder delivery, thus overcoming the above problems.

Energy-saving and environmental protection.

Most of the current plasma surfacing machines on the market are based on three-phase electricity (380v), gas consumption between 4-8, powder. The WALDUN plasma welding machine uses a two-phase power supply (220v) with a gas consumption of 1-2%. The powder utilization rate is around 90%. This, in turn, saves production costs.

PTA hardfacing for lead screw

Ordering a plasma transferred arc coating machine from WALDUN

In some cases, we can modify your equipment to incorporate these plasma transferred arc coating machine when not in the original equipment design. If your equipment has lost some efficiency or does not hold the same tolerances as new, inspect the worn parts. There could be an easy and cost effective fix to the problem.

PTA Welding Machine – The Ultimate FAQ Guide

PTA, or Plasma Transferred Arc Welding, is a welding process to create a high-density arc.

PTA Welding  machine is used for PTA Welding. Below is the Ultimate FAQ Guide.

What are the features of a PTA welding machine?

PTA hardfacing machine for lead screw

  • The cladding alloy layer added to the workpiece matrix with high bond strength.
  • It has fast cladding speeds with low dilution rates.
  • The cladding layer is dense and beautifully formed.
  • Plasma welding can directly use on the surface of rusted and oiled metal parts.
  • Easy mechanization and automation.
  • It has a simple structure, energy-saving, and easy operation.

What are the applications of PTA welding machine?

Tungsten Carbie PTA Welding

People are using PTA welding machine in petroleum, chemical, engineering, mining, and other industries.

Sealing welding of various types of valves.

Repair of worn oil drill pipes, bearings, shafts, rollers, wrenches, etc.

What is the classification of PTA welding machine?

PTA Hardfacing

PTA welding machine has several types.

(1) Cold-wire plasma welding

Use cold wire plasma welding wire as a filler material, without preheating directly into the welding zone for welding.

(2) Hotwire plasma welding

Hotwire plasma welding uses welding wire resistance of its own preheating and then sent to the plasma area for welding, single wire, or double wire feeding.

(3) Prefabricated plasma welding

Alloy is prefabricated into a specific shape and placed on the surface to be surfaced, which is then plasma melted to form the welding layer.

(4) Powder plasma welding

Powder plasma welding is a welding method in which alloy powder is fed into a plasma arc and melted to create a welding layer. Alloys are mostly made into powder, so powder plasma welding is available in a wide range of materials and is not limited by the ductility of materials like wire.

What is powder PTA welding?

PTA hardfacing for lead screw

The alloy powder commonly used in powder plasma arc welding is mainly self-fusing alloy powder and composite powder.

Self-fusing alloy powder

Self-fusing alloy powders include nickel-based, cobalt-based, iron-based, copper-based, etc. The iron-based alloy powders are widely used because of the vast raw materials, low price, and good performance.

The iron-based alloy powder is widely used because of the complete raw materials, low price, and good performance.

However, nickel and cobalt are scarce metals with high costs and are generally only used for welding with unique surface properties.

(1) Nickel-based self-fusing alloy powders are divided into nickel boron silicon series and nickel-chrome boron silicon series.

(2) Cobalt-based self-melting alloy powder: B and Si elements are added to the cobalt-chromium-tungsten alloy to form. The cobalt-based self-fusing alloy has excellent high-temperature performance, good hot strength, corrosion resistance, and thermal fatigue resistance. It is more suitable for a high temperature of 600 ℃ ~ 700 ℃ work of oxidation resistance, corrosion resistance, wear-resistant surface coating. Such as high-pressure valve sealing surface welding.

(3)Iron-based self-fusing alloy powder can be divided into two types: austenitic stainless steel type self-fusing alloy and high chromium cast iron type self-fusing alloy.

(4) Copper-based self-fusing alloy powder: copper-based alloy scratch resistance, good plasticity, easy to process. Mainly tin-phosphor bronze powder and add nickel white copper powder.

Composite alloy powder

Composite powders are composed of two or more solid phases with different properties.

The composite powder structure can generally be divided into coated, non-coated, and sintered, and other different categories of powder.

What is PTA powder welding?

Tungsten Carbie PTA Welding

PTA powder welding, using the high temperature generated by the plasma arc, the alloy powder, and the substrate’s surface, will be rapidly heated and melted, mixed, diffused, and solidified together. The plasma beam leaves and cools itself to form a high-performance alloy layer. It strengthens and hardens the surface of your parts.

Plasma overlay welding VS Plasma spraying

SAMSUNG DIGITAL CAMERA

In principle, the plasma arc is used to generate back to the heat source will be melted powder attached to the workpiece’s surface after the process.

Plasma arc welding consumables and the workpiece bonding strength is better. The metallurgical bonding, the welding layer thickness is thicker.

Plasma arc spraying is suitable for a thin layer, extensive area welding; the arc column is long and can be far from the workpiece welding.

Plasma welding VS laser welding

Plasma is arc welding, the laser is photothermal welding, and plasma is generally more efficient than laser. But extreme field lasers are more suitable.

Laser welding is the process of adding a cladding material to the surface of a substrate, using a high energy density laser beam to melt and condense it together with a thin layer. To form an additional cladding layer on the substrate’s surface, which is a metallurgical combination with the material.

What is the difference between two layers and one layer of the PTA welding machine?
plasma cladding machine

Welding one layer is better in terms of strength.

If the dilution rate in terms of welding two layers better.

Another defect with the base material is what the material is related to the base material’s general hardness is less welding defects.

The thicker the cladding layer, the greater the probability of defects.

Plasma cladding VS Plasma welding VS Plasma spraying

Although they are all plasma welds, cladding, overlays, and blasting are not one process.

Plasma cladding is when alloy powder is used as filler metal, which is heated and melted together with the substrate surface to form an alloy layer.

Plasma welding is applied to repair thicker base materials, such as coal mills, cement mills, and rolls.

Plasma welding is used to repair components with thin base material or suitable for weldings, such as high-pressure boiler tube wall spraying and fan blade spraying.

What gases are used for PTA powder welding?

Advantages of Plasma Welding

PTA powder welding is not recommended to use a mixture of gas. It is recommended to use argon gas. It is better to use mixed gas for welding only.

What is the reason that the hardness of plasma powder welding does not meet the standard?

First: different grades of alloy powder (welding consumables) have a corresponding hardness; you can see if the alloy powder problems.

Second, if a specific grade of powder hardness of HRC50, but the hardness after welding is not 50 degrees, it is possible to surface the thickness of too thin.

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