Plasma arc welding and plasma transfer arc welding

How Plasma Transferred Wire Arc Welding Works

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Typically, remanufacturing a block requires iron-cast parts, custom welding and an intricate machining processes. Plasma Transferred Wire Arc technology works by using a traditional coating wire which is exposed at high pressure from atomizing gas mixed with plasma gas surrounded by a cathode. The cathode heats up electronically via the arc of the wire and the combination of both gasses are expelled via a

nozzle and released by a particle jet stream evenly over the engine block surface.

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Plasma Transferred Wire Arc (PTWA) differs from traditional plasma arc welding techniques which are known as Wire Arc Spray Welding (WASW). PTWA relies on just the one wire for the metallic substance (feedstock) where as WASW relies on two metal wires which are independently fed into the spray gun. The charged wires create an arc and the heat of the two wires are melted to form molten material which is air fed by a jet to fill the weld. With PTWA welding the molten particles are then instantly flattened due to their high kinetic energy, then solidify upon contact to form crystalline and amorphus phases. With PTWA technology the plasma gas usually contains a higher amount of nickel which produces a gel like substance that bonds tight with cast iron or aluminum. It is possible to produce multi-layer coatings with PTWA welding. Using a different substrate in the feedstock can produce a base layer of particles that are primed for a secondary "sealer" layer of particulate matter that bonds on top of the first weld. This secondary coating makes for a highly wear-resistant coating. PTWA is typically used in engine components such as blocks, connecting rods, cylinder heads or bushings. With Transferred Wire Arc Welding either wire metal alloys can be used in the feedstock or a powdered form of a metal alloy. The most common powdered alloy to use is Cobalt #6 with a supplement of Nickel for better bonding strength at the substrate. In recent years companies have chosen to opt more for powered feedstock as it is at times 50% cheaper than traditional wire alloys.

The plasma generator or gun head consists of a tungsten cathode, an air-cooled pilot nozzle made of copper, an electricity conductive consumable wire which is the know as the anode. The head is mounted on a rotating spindle, which rotates up to 600 rpm. The wire is fed perpendicularly to the center orfice of the nozzle. The plasma gas is introduced through tangenital boreholes situated in the cathode holder to ensure a vortex is created. The entire process from creation of the arc to the delivery of the weld into the substrate happens all within .00050 seconds.

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