Presentation on Plasma Technology Uses In Metallurgy & Metal Working Industry By Mr. Arun Kumar (Managing Director - Technocrats Plasma Systems Private Limited).

1. PLASMA TECHNOLOGY
IN METALLURGY &
METALWORKING
Presented By
Mr. Arun Kumar
MANAGING DIRECTOR
Technocrats Plasma Systems Pvt Ltd

2. WHAT IS PLASMA
Plasma is popularly known as 4th state of matter, other three
being Solid, Liquid & Gas.
After the gas is heated or external energy is applied to the gas, it
gets ionized and plasma is formed. Plasma conducts electricity.
It’s a very hot substance. Plasma exits in nature as well.
Plasma is generated in a specially designed gun called plasma
torch using electrical power for various engineering applications
including metal cutting. The process is known as Plasma
cutting.
Plasma cutting is becoming increasingly popular these days due
to its advantage over conventional method of cutting metals.
Plasma can cut all conducting metals such as SS, MS, AL,
COPPER, BRASS, INCONEL and MONEL etc.

4. APPLICATION OF PLASMA IN
METALLURGYAND METAL WORKING
Application of Plasma
in Metallurgy & Metal
working
Melting &
Steel
Making
Surface
Modification
& Coating
Welding
Cutting &
Gouging

5. Steel Making

6. Plasma Furnaces

7. Advantages of Plasma Furnaces
The plasma arc furnace is a device to melt a substance by
low-temperature plasma flow, typically created by an
electric arc heater (plasmatron). The main field of
application of the plasma furnace is electrometallurgy.
The main advantages of a plasma furnace are:
• high stability of the working process and an opportunity of
continuous temperature adjustment by changing the
plasmatron electric conditions
• the opportunity of operation in practically any desired
atmosphere
• high degree adoption of alloying additions

8. • a decrease of the impurities content and, consequently,
an opportunity of smelting low-carbon steels and alloys
• an opportunity of smelting the nitrided steels by usage of
gaseous nitrogen
• a relatively small pollution of ambient air
Various direct current (DC) and alternating current (AC)
plasmatrons are used in plasma furnaces. In large-scale
plasma furnaces, several plasmatrons are used to provide
more homogeneous heating

9. Surface Modification & Coating by Plasma
Low Pressure Plasma Technology is used for-
1. ADHESION PROMOTION
2. CLEANING
3. HYDROPHILIC PROPERTIES
4. OLEOPHOBICITY AND HYDROPHOBICITY
5. LOW-FRICTION COATING
6. BARRIER COATINGS
7. STERILIZATION

10. Plasma Spraying
Thermal Spray
This is the method of applying materials onto a prepared
base material by heating particles in the stream of a heat
source, creating a semi-molten state. Particles are then
propelled by high velocity onto a prepared substrate where
they adhere to the base surface via a mechanical bond.
Particles continue to build until a specified thickness is
attained. This technique is considered the "cold method of
welding", whereas high temperatures can be achieved in
the heated pocket, while the temperature of the part itself
usually remains under 200°F.

11. Typical physical specifications of coatings:
• Maximum hardness of 72 Rc hardness (Tungsten
Carbides)
• Surface texture as sprayed is rough, from 150 to 1000+
Ra
• Thickness range from .002 to .150
• Bond strength range: 2500 -15000 PSI
Advantages
• No degrading of parts due to heat warping and distortion
• No degrading of part metallurgy or integrity
• Surfaces are enhanced to provide improved performance

12. One of the Core Coating Application Techniques is-
Plasma Spray: In this process we use various gasses that
are ignited by an electric arc. Temperatures can rise up to
30,000° F while the part temperature remains at less than
200°F. Particle velocity is greater than in the other four
systems. One of the benefits of using this system is the
high heat, which can process materials with high melting
points (including ceramics).

14. Advantages of Plasma Spraying
• A wide range of coating materials to meet many different
needs, with virtually all materials available in a suitable
powder form.
• Higher quality coatings than other more conventional
thermal processes such as flame or electrical arc
spraying.
• Many types of substrate material, including metals,
ceramics, plastics, glass, and composite materials can be
coated using plasma spraying.
• The high temperature of a plasma jet makes it particularly
suitable for spraying coatings of refractory metals and
ceramics, including ZrO2, B4C and tungsten.
• A broader powder particle size range can be used,
typically 5-100µm, compared with HVOF spraying.
• Plasma spraying is a well-established coating process
that is widely available and well understood.

15. USE OF PLASMA IN FORGING
Forging is a metalworking process where a work piece is
shaped by compressive forces using various dies and
tools.
During forging, high mechanical, chemical and thermal
cyclic loads acting simultaneously which leads to a failure
of the form giving tool components after a short tool life.

16. Accounting for about 70% of all causes
‘Plasma Nitriding’ is the best surface hardening treatment.
It is done through Plasma Nitriding Suite consisting of
Vacuum Chamber; Pulsed Plasma Generator; System
Controller; Vacuum System and Gas Supply System.

17. USE OF PLASMA IN ROLLING
Rolling is a direct compression deformation process, which
reduces the thickness or changes the cross section of a
long work piece.
Use of Plasma Cutting Machines is very popular in Rolling
mills across Europe. Plasma cutting machines are used to
cut the foils, sheets or plates at a desired length

18. USE OF PLASMA IN TUBE/
SHEET FORMING
• Plasma coating is extensively used for hardening the
surfaces of sheet or tube
• Plasma cutting machines are used to cut sheets and
billets at desired length
• Plasma cutting machines along with pipe cutting
attachments are used to cut tubes and pipes at desired
length
• Plasma Cutting machines often replaces shearing
machines in the process of sheet forming

19. Automatic Billet Cutting
with Plasma

20. USE OF PLASMA IN MACHINING
-Plasma arc can be used for Removing material
from the surface of rotating cylindrical jobs.
-Also, Plasma arc can be used for softening of
metal by placing the arc before cutting tool in
Sophisticated Lathe machines to make the metal
soft, which increases the metal removal rate.

21. PLASMA CUTTING
MYTH REALITY
Plasma Cutting is only for SS Plasma can cut any electro
conductive material like SS, MS, Al,
Cu, Zn, Ag, Sn, etc
Plasma cutting is a costly process Plasma cutting is up to 80%
cheaper than gas cutting
Plasma Cutting needs high safety
measures
Plasma is safer than gas as it does
not use fire or cylinders
Plasma Cutting needs skilled
workers
It is easier to cut in plasma as the
process is fast & hence requires
less time for concentrating on the
job

22. PLASMA CUTTING PROCESS

23. Types of Plasma Cutting Machines
Manual Power Source
Semi-Mechanized
Cutting Machine
Manual Torches
Manual Plasma Cutting Machines

24. MECHANIZED CUTTING
MACHINE

25. CNC CUTTING MACHINE

26. Sample Cut Pieces

27. Sample Cut Pieces

28. CNC PIPE PLASMA/GAS
PROFILE CUTTING MACHINE

29. Pipe Profile Cutting with Plasma

30. Sample Cut Samples

31. COST BENEFIT OF PLASMA
CUTTING OVER CONVENTIONAL GAS
CUTTING
Cost of Mild Steel (MS) cutting with Gas
“As per empirical formula, 6 Cylinder of Oxygen & 1
Cylinder of LPG can cut 1200 mm-Meter”
Plate
Thickness
Length Cut Cost of
LPG(@ Rs.
2000/Cylind
er)
Cost of
Oxygen(@
Rs.
200/Cylinde
r)
Cost of
Consumabl
e
Labor Cost
(@Rs. 50/Hr
& Cutting
speed
@200 mm-
Meter/Hour
)
Total Cost Cost
(Rs./Meter)
5 240 2000 1200 80 300 3580 14.92
10 120 2000 1200 80 300 3580 29.83
15 80 2000 1200 80 300 3580 44.75
20 60 2000 1200 80 300 3580 60

32. Cost of Mild Steel (MS) cutting with CNC Plasma Profile
Cutting Machine
Plate
Thickness
Length Cut
per Hour
Electricity
Cost
(@18.5
KW/Hr &
Rs. 8/KW)
Consumabl
e Cost
Labor Cost
(Operator
cost @ Rs.
75/Hour)
Total Cost Cost
(Rs./Meter
)
5 105
(@1.75m/
min)
148 400 (2
Sets)
75 623 5.95
10 90
(@1.5m/mi
n)
148 600 (3
Sets)
75 823 9.15
15 72 (@1.2
m/min)
148 800 (4
Sets)
75 1023 14.2
20 56 (@0.93
m/min)
148 800 (4
Sets)
75 1023 18.3

33. Savings by CNC Air Plasma Cutting over Gas Cutting
Plate Thickness Cutting Cost with
Gas Cutting (Rs.
Meter)
Cutting Cost with
Plasma Cutting
(Rs./Meter)
Savings (Rs./Meter)
5 14.92 5.95 8.97
10 29.83 9.15 20.68
15 44.75 14.20 30.55
20 60 18.30 41.70

34. USE OF PLASMA IN WELDING
1. Micro Plasma Welding
-used for very thin foil welding of 0.01 mm to 1 mm approx
2. Plasma Welding
-used for key hole welding

35. 3. Plasma Transferred Arc
-used for repairing welding, deposition, etc.

36. ANY QUESTIONS ???

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