Micro Plasma Welding

Micro-plasma welding technology is known for its excellent welding precision and control, making it ideal for applications that place extremely high demands on joint quality. From medical devices to precision engineering, our product range is designed to meet all your precision welding needs.

Micro Plasma Arc Welding

Deewi Automation stands as a leading manufacturer, supplier, and exporter of top-notch Micro Plasma Welding (MPW) Machines. Utilizing the Precision Micro Plasma Arc Welding Machine with a welding current ranging from 0.1 to 40A, we offer unparalleled welding solutions. With our technology, you can achieve precise welding even on thin sheets, guidewires, and pipes as small as 0.1mm in size.

Our product range:
Portable Micro Plasma Welding Machine: Designed for small studios and mobile operations, combining portability and high performance.
Benchtop microplasma welding systems: ideal for laboratories and manufacturing lines, offering more advanced control capabilities and automation options.
Customized microplasma welding solutions: customized for specific applications and production needs, including automated workstations and integrated systems.
Why Choose Our Micro Plasma Welding Solutions?
Choosing our micro-plasma welding products means choosing unparalleled precision and reliability. Our equipment is carefully designed and rigorously tested to ensure consistent, high-quality welding results in a variety of challenging conditions. No matter the size of your project, our dedicated team will provide you with personalized consultation to ensure you find the solution that best suits your needs.

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What Is Micro Plasma Welding?

Micro Plasma Arc Welding (MPAW), a subset of Plasma Welding, Micro Plasma Welding is of the important arc welding process, shares similarities with TIG welding in terms of its arc formation. However, what sets it apart is its ability to adapt to various welding scenarios by adjusting nozzle apertures and plasma gas flow rates, resulting in three distinct energy modes: Micro plasma (0.1 to 15A), Medium current (15 to 100A), and Keyhole plasma (over 100A). Each mode finds its unique application.
Microplasma welding, in particular, is remarkable due to its stable, columnar arc. It exhibits exceptional precision, allowing for welding tasks on delicate materials such as sheets as thin as 0.1mm, intricate metal wires, and mesh structures. This technique finds widespread use in welding applications for medical guidewires, ball tip guidewires, Wire & Rod End Rounding, Wire Binding, Light Bulb Filaments, Wire Mesh Welding, and more.

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If you have any questions about micro plasma welding technology or products, or need professional advice, don’t hesitate to contact our customer service team today. We are committed to providing the best support and solutions for your precision welding needs.

The composition of the Micro Plasma Arc Welding Machine.

The common components of a Micro Plasma Arc Welding Machine typically include:

Power supply
Water cooling system
Micro Plasma Welding Torch
Feeding system
Welding table
Plasma Console
Fixtures
Process controller
Gas supply
Pilot arc control

Precision Micro Plasma Welding Machine Host Parameters

DW-MPW01A.

Main technical parameters and models	Data
Arc current (a)	2.0-5.0
Welding current (a)	0.1-10-40
Base current (a)	0.1-10-40
Rise time (s)	0.0-5.0
Descent time (s)	0.0-5.0
Welding time (MS)	1-500
Interval time (MS)	10-500
Air delivery in advance (s)	1-10
Gas time delay (s)	1-20
Ion gas (L / min)	0.25-2.5
Protective gas (L / min)	1-25
Input voltage (V)	AC220V，50HZ
Rated input capacity (kVA)	1.1
Load duration rate (%)	60
Weight (kg)	28
External dimension of power supply (mm)	590330300

DW-MPW01A

Benefits of Micro Plasma Welding:

Micro Plasma Welding can be considered an upgraded version of Tungsten Inert Gas (TIG) welding process. Its most significant feature is the ability to perform welding in very small dimensions with high precision. Beyond its capability to weld extremely small parts, Micro Plasma Welding offers several advantages:

It can handle exceptionally delicate welding tasks, achieving high precision even on tiny workpieces.

Unlike argon arc welding, the plasma arc remains stable even at low welding currents (less than 3A).

Due to concentrated heat during welding, the process is faster, resulting in shorter welding times. In large-scale production, full automation can be achieved, significantly enhancing welding efficiency and quality.

The welding process is rapid, resulting in a smaller heat-affected zone and quicker cooling time. Consequently, minimal heat damage or distortion occurs, The ability to weld very thin materials without perforation.

It can weld various metals, including stainless steel, non-ferrous metals, and metals with high melting points.

High-frequency noise only occurs during arc initiation, resulting in minimal working noise.

Compared to Micro Laser Welding, Micro Plasma Welding equipment is more affordable.

Quick Q&A – About Micro Plasma Welding.

Regarding ‘Micro Plasma Welding’, here are some common questions and their answers:

A1: Micro Plasma Welding is a technique that involves controlling the plasma arc to achieve precise welding results. It operates at very low currents (typically in the range of 0.1 to 15 amperes), making it suitable for the precision welding of materials with thicknesses ranging from several micrometers to a few millimeters.

A2: Micro Plasma Welding has the advantage of being relatively low in cost, with simple equipment and high welding efficiency. It also allows for continuous energy adjustment, which is conducive to automation. However, compared to laser welding, its weld seam precision and consistency may be slightly inferior. Laser welding offers extremely high welding speeds and precision, but the equipment and operational costs are higher.

A3: Micro Plasma Welding is conducted at lower currents, with a very stable welding arc and a small heat-affected zone, making it particularly suitable for welding thin plates and sensitive materials. In contrast, traditional TIG (Tungsten Inert Gas) welding typically occurs at higher currents and is suitable for thicker materials.

A4: “Needle arc micro plasma welding” is not a standard industrial term; it may be considered a special application or variant of micro plasma welding technology, typically used for especially precise or small-scale welding tasks. This technique employs an extremely fine plasma arc, commonly used for welding thin materials such as in electronic components, micro-mechanical parts, or fine metal components.

A5: Micro Plasma Welding is suitable for a variety of materials, including but not limited to stainless steel, titanium alloys, nickel-based alloys, and some non-ferrous metals like aluminum and copper.

A6: When selecting filler material, one should consider the chemical composition and heat treatment state of the base material to ensure that the filler material has a similar coefficient of thermal expansion and melting point. Additionally, the filler material should possess good flowability and formability.

A7: Controlling the parameters in Micro Plasma Welding typically involves setting the appropriate current, gas flow, welding speed, and arc length. These parameters must be adjusted according to the type and thickness of the material, as well as the desired characteristics of the weld seam.

A8: As a precision welding process, Micro Plasma Welding does demand a relatively high skill level from the operator. The operator must have a thorough understanding of the welding process and be capable of precisely controlling the various parameters. However, as automation becomes more advanced, the technical demands on workers are continuously decreasing.

A9: Safety measures include, but are not limited to, using personal protective equipment such as protective eyewear, gloves, and face shields. Ensuring good ventilation to prevent the accumulation of harmful gases, and strictly adhering to operational procedures to avoid electric shock and exposure to ultraviolet radiation.

A10: Maintenance of micro plasma welding equipment involves regular cleaning and replacing worn parts like electrodes and nozzles, inspecting hoses and connections regularly, maintaining good gas flow, and ensuring the stability of power sources and control systems.

A11: A Micro Plasma Welding Torch is a key tool in performing micro plasma welding processes. It is used to generate and control a very fine plasma arc, thus allowing precise control over the welding process to accomplish precision welding tasks.

A12: Micro Plasma Welding is highly suitable for automated production since it allows for precise control of welding parameters, and the welding process is easily programmable and repeatable. Automated production lines can enhance the consistency of weld quality and production efficiency.

A13: Automation in micro plasma welding can be achieved through the use of computer numerical control (CNC) systems, which include programming welding paths, controlling welding speed and current, and automatically adjusting the position of the welding head, as well as automatic wire feeding mechanisms to ensure consistency in weld quality.

A14: Defects that may occur in micro plasma welding include weld bead protrusion, porosity, cracks, lack of fusion, and burn-through. These are usually the result of inappropriate welding parameters or poor operational techniques.

A15: Strategies to prevent burn-through include using low current settings, controlling the welding speed, optimizing gas shielding, and implementing pulse welding techniques to manage heat input.

A16: To avoid an oversized HAZ, the following measures can be adopted:

Employ the lowest possible current settings to minimize heat input.
Increase welding speed to reduce the accumulation of heat.
Utilize pulse welding modes to limit heat input.
Implement cooling techniques, such as water or gas cooling, where appropriate.

A17: Efficiency can be increased through:

Optimizing welding parameters to shorten welding time.
Employing automated equipment to minimize manual operations.
Conducting process optimization, such as using pulse welding to enhance weld quality and reduce subsequent finishing work.

A18: Managing the weld transition zone requires precise control, typically through:

Accurate welding path planning to ensure a smooth transition between the weld seam and the base material.
Appropriate setting of heat input to avoid significant differences in hardness and microstructure between the weld and the base material.
Gradually reducing the current towards the end of welding to avoid cracks or holes at the stopping point.

A19: Quality monitoring can be conducted by:

Using online monitoring systems, such as camera equipment paired with monitors to watch the weld formation process.
Real-time monitoring of welding parameters such as current, voltage, and gas flow during welding.
Post-weld evaluation of weld quality through non-destructive testing techniques (such as X-ray or ultrasonic testing).

A20: The choice of shielding gas depends on the material being welded. Commonly used shielding gases include:

Inert gases, like argon or helium, for welding materials such as titanium alloys or stainless steel.
Active gases, like small proportions of oxygen or hydrogen, for certain special applications to improve weld quality.
Gas mixtures, such as argon + hydrogen or argon + carbon dioxide, to provide a better appearance or welding performance.

A21: Micro plasma welding is widely used in aerospace, microelectronics, precision instrumentation, medical equipment, and jewelry manufacturing.

A22: In medical device manufacturing, micro plasma welding is used to join small or thin-walled metal components, such as surgical instruments and implant devices. Its precise welding capability ensures the strength and cleanliness of the joints, meeting the high standards of the medical industry.

A23: In aerospace, micro plasma welding is used for manufacturing and repairing high-performance alloy components, such as engine parts and structural components. Its ability to provide high-quality welding solutions is critical for ensuring flight safety.

A24: Although primarily used for thin materials, micro plasma welding can also be applied to precision pipeline welding, especially where thin walls, small diameters, and high-precision welds are required.

A25: Micro plasma welding can be suitable for multi-layer welding, especially when precise thermal gradients between layers are needed or when dealing with heat-sensitive materials. However, each layer must be precisely designed and controlled to avoid welding defects.

A26: Micro plasma welding requires a well-controlled environment to reduce contamination and temperature fluctuations that could affect weld quality. Additionally, proper ventilation is important to ensure the safety of the operator and the cleanliness of the welding area.