Process for coating or welding easily oxidized materials and plasma torch for carrying out this process

• US 6,133,542 A
• Filed: 09/20/1999
• Issued: 10/17/2000
• Est. Priority Date: 07/04/1996
• Status: Expired due to Fees

• Current Assignee: MEC Holding GmbH (Messer Adolf Family)
• Original Assignee: Castolin S.A.
• Inventors: Dvorak, Michael, Robert, Patrice
• Primary Examiner(s): PASCHALL, MARK H
• Application Number:
  US09/214,352
• Time in Patent Office: 393 Days
• Field of Search: 219/121.47, 219/121.52, 219/121.54, 219/121.57, 219/121.51, 219/74, 219/75, 219/76.16, 219/121.46
• US Class Current: 219/121.47
• CPC Class Codes: B23K 10/027 Welding for purposes other than joining, e.g. build-up welding
• CPC Class Codes: H05H 1/34 Details, e.g. electrodes, nozzles
• CPC Class Codes: H05H 1/3421 Transferred arc or pilot arc mode
• CPC Class Codes: H05H 1/3478 Geometrical details

Abstract

A process for coating or welding easily oxidized materials is carried out by applying weld metal powder by a plasma powder welding process with an alternating current or with a direct current and a superimposed alternating current as welding current to generate a plasma arc for the powder welding process. For this purpose, one base of the plasma arc is produced in a spherical recess (34) of an electrode (32).

Claims

1. A process for coating oxidizable materials by plasma build-up welding of powdered additives with a plasma transferred arc which comprises applying a current selected from the group consisting of an alternating current of a frequency between about 10 to 100 Hz and a direct current which is super imposed with alternating current of a frequency between about 10 Hz to 200 KHz for generating the plasma transferred arc for powdered hard surfacing wherein a base point of the plasma arc is produced at a spherical position formed on an electrode.

2. A process according to claim 1 wherein the superimposed alternating current is at a frequency of between about 10 to 100 Hz.

3. A process according to claim 1 wherein the superimposed alternating current is at a frequency of 1000 between about 1 and 200 KHz.

4. A process according to claim 1 wherein superimposed on the direct current is a medium-frequency voltage as the alternating current.

5. A process according to claim 1 wherein superimposed on the direct current is a high-frequency voltage as the alternating current.

6. A process according to claim 1 wherein superimposed on the direct current is a rectangular voltage as the alternating current.

7. A process according to claim 1 including conducting flow of the gases at controlled flow velocity, such that oxides produced are broken up and moved to the edge of a resulting molten bath.

8. A process according to claim 1 wherein a coating of an anti-abrasion layer of the following composition is produced:

Si 5.0 percent by weight;

Cu 3.0 percent by weight;

Mg 0.5 percent by weight;

remainder Al.

9. A plasma burner with rod-type cathode as well as a gas channel of a burner nozzle enclosing this cathode, which burner nozzle is followed by a nozzle opening with a more narrow cross-section, for implementing the process according to claim 1 wherein the spherical portion is formed on the cathode of the plasma burner towards the end thereof.

10. A plasma burner according to claim 9 wherein the spherical portion on the cathode is roughly tangent to a plane (E), which is determined by the front surface of an anode assigned to the cathode and containing the nozzle opening.

11. A plasma burner according to claim 9 wherein the spherical portion on the cathode rises above a plane (E) at a distance, wherein the plane is determined by the front surface of an anode assigned to the cathode and containing the nozzle opening.

12. A plasma burner according to claim 9 wherein the spherical portion on the cathode lies within an anode enclosing the latter and containing the nozzle opening at a distance (a) from a plane (E), which is determined by the front surface of the anode.

13. A plasma burner according to claim 11 wherein the distance between the spherical portion and the front surface (17) is 4 mm at most.

14. A plasma burner according to claim 12 wherein the distance between the spherical portion and the plane (E) is 4 mm at most.

15. A plasma burner according to claim 9 wherein a transition between a gas channel and the narrow nozzle opening comprises a shoulder recess which faces the spherical portion on the cathode at a gap distance.

16. A plasma burner according to claim 10 wherein a transition between a gas channel and the narrow nozzle opening comprises a shoulder recess which faces the spherical portion on the cathode at a gap distance.

17. A plasma burner according to claim 11 wherein a transition between a gas channel and the narrow nozzle opening comprises a shoulder recess which faces the spherical portion on the cathode at a gap distance.

18. A plasma burner according to claim 12 wherein a transition between a gas channel and the narrow nozzle opening comprises a shoulder recess which faces the spherical portion on the cathode at a gap distance.

19. A plasma burner according to claim 15 wherein a cylindrical section of the gas channel is connected to a ring-type shoulder recess as the seat for the spherical portion on the cathode.

20. A plasma burner for generating an arc according to claim 9 wherein the cathode determines the base point of the arc.

21. A plasma burner according to claim 9 wherein the cathode which is subjected to the current is water-cooled.

22. A plasma burner according to claim 20 wherein the cathode has a water-cooled supporting body and an interchangeably connected cathode part made of high-melting material with low thermal conductivity for the base point of the arc wherein the supporting body comprises copper.

23. A plasma burner according to claim 22 wherein the interchangeable cathode part comprises tungsten for infiltration and tungsten as an impregnating material.

24. A plasma burner according to claim 23 wherein the tungsten for the interchangeable cathode part is alloyed with thorium.

25. A plasma burner according to claim 22 wherein the interchangeable cathode part is manufactured from a high-melting material selected from the group consisting of nitride, carbide, boride, silicide, titanium carbide, and titanium carbide sintered alloy.

26. A plasma burner according to claim 22 wherein the interchangeable cathode part is manufactured with an impregnating material with a low sputter rate.