What is Plasma Welding? Truly Comprehensive Tips

Marcus Colson Last updated on September 3, 2023
Reading Time: 6 Minute

Plasma welding has come a long way since its introduction in the early 1960s. Though similar to TIG welding, this process uses a plasma arc to achieve deeper and more controlled welds.

In this blog post, we’ll break down the what, how, and why of plasma welding—from its characteristics to its advantages and limitations.

If you’ve been interested in the world of welding, you’ll find this article a treasure trove of actionable insights.

What Makes Plasma Unique?

Characteristics of Plasma

One of the remarkable aspects of plasma in welding is its temperature. With the capability to reach up to 30,000 degrees Fahrenheit, it’s not just hot; it’s extraordinarily hot.

This extreme temperature allows the plasma to become highly conductive, which is a significant benefit for creating strong, high-quality welds. The plasma arc, when formed, is both concentrated and highly ionized.

This unique set of characteristics allows for focused energy, making it easier to achieve specific welding outcomes, be it depth of penetration or the width of the weld bead.

Operating Modes

Let’s delve into the three primary operating modes in plasma welding.

  1. Microplasma Welding (0.1 – 15A):

For intricate work on thin sheets and foils, microplasma welding is almost tailor-made. If you’re working with delicate materials, this mode is your best bet.

The low current settings give you the level of control you need without compromising the quality of the weld. It’s particularly useful for industries requiring fine work, like medical device manufacturing or specialized electronics.

  1. Medium Current Welding (15 – 200A):

If you’ve worked with TIG welding before, you’ll find that this mode gives you a similar, but enhanced, experience.

This is where plasma welding shines with its deeper penetration capabilities. The reason lies in the higher plasma gas flow, which aids in concentrating the energy better than in conventional TIG processes.

Therefore, for jobs requiring moderate thickness but high-quality welds, medium current welding is a powerful choice.

  1. Keyhole Welding (Over 100A):

When you’re facing tasks that involve thicker materials, keyhole welding should be on your radar. It produces a plasma beam powerful enough to fully penetrate thick materials, often in a single pass.

Imagine the amount of time and effort this can save on bigger projects. While Submerged Arc Welding (SAW) also works for thick materials, keyhole welding in plasma offers full penetration with a single pass, something that is generally harder to achieve with SAW.

Equipment You’ll Need

While the basics of the equipment remain similar to TIG welding, there are some specifics to note:

  • Power Source: You’re typically going to use a Direct Current (DC), constant current power source. This ensures stable and reliable welding operations.
  • Plasma Control Console: Think of this as an added layer of control. It’s an additional component that can be integrated with a standard TIG power source to manage the plasma gas flow and current settings.
  • Electrode: The electrode is usually made of Tungsten-2% thoria. It’s durable and can withstand the high temperatures, making it ideal for plasma welding.
  • Plasma Nozzle: The nozzle is crucial in directing the plasma arc. Usually made of copper, its bore diameter is critical to the process. An incorrectly sized bore can negatively impact the quality of the weld.
  • Wire Feeder: If you’re looking into machine or automatic welding, a wire feeder may be a good investment. It automates the feeding of filler material into the weld pool, making the process more efficient.

How Do You Start and Maintain the Arc?

Initiating and sustaining the arc in plasma welding is crucial for effective results. Without a stable arc, the quality of your weld may suffer. So, how do we go about it?

Arc Initiation

  • High Frequency (HF) Initiation: The arc is first initiated using High Frequency (HF). This is a reliable method for getting your arc started and offers a level of consistency that can be essential for high-quality welding.
  • Pilot Arc Formation: After HF initiation, a ‘pilot’ arc is formed between the electrode and the plasma nozzle. This is a preliminary arc that enables the main arc to be struck easily.

Arc Maintenance

  • Pilot Arc System: The pilot arc system ensures that the arc is stable throughout the welding process. This removes the need for continuous HF re-ignition, which can be both annoying and detrimental to the weld.
  • Arc Stability: One of the advantages of plasma welding is the incredible arc stability it offers, which is far superior to other types of welding like carbon arc welding (CAW) or submerged arc welding (SAW).

Important Tips for Arc Maintenance

  • Regularly Check Equipment: Equipment such as the tungsten electrode and copper plasma nozzle should be in good condition for the arc to remain stable.
  • Quality of Power Source: Make sure you’re using a reliable DC, constant current power source for best results.

Incorporating these procedures and tips into your workflow can significantly improve your plasma welding experience.

You’ll find that maintaining the arc becomes almost second nature after a while, leaving you free to focus on the intricacies of your project.

Whether you’re working on aerospace components or just some DIY, a stable arc is your key to a successful and effective weld.

Which Gases Can You Use?

Selecting the appropriate gas can make a significant difference in your welding outcome.

  • Plasma Gas: More often than not, argon is the go-to choice. Its properties make it ideal for creating a stable and focused arc.
  • Shielding Gas: Typically, you’ll use either pure argon or a mix of argon and 2 to 5% hydrogen. The hydrogen enhances the heat output, aiding in better weld penetration.
  • Alternative Gases: Helium is an option but comes with its own limitations, such as lower arc stability and higher cost. It’s mostly used for specific applications where the advantages outweigh the disadvantages.

Read Also : Welding GAS Cylinder Sizes: Discover the Best Gases

Advantages and Disadvantages

Why Choose Plasma Welding?

When you’re evaluating welding methods, plasma welding comes up with some standout benefits:

  1. Greater Energy Concentration: Plasma welding offers higher energy concentration compared to other techniques like Gas Tungsten Arc Welding (GTAW). What does this mean for you? Well, you can accomplish more focused work, and that translates into more control over the welding process.
  2. Deeper, Narrow Penetration: If you’ve struggled with getting sufficient depth in your welds, plasma can be the solution. It has an innate ability to reach deeper into materials, giving you welds that are not just surface-level. In fact, compared to Electroslag Welding (ESW), plasma welding offers a much finer degree of control over penetration.
  3. Stability and Flexibility: Arc stability is often a concern in welding, but the pilot arc system in plasma welding helps achieve exceptional stability. This is crucial when you’re working on tasks that require precision. Moreover, plasma welding gives you more freedom during manual welds. You’re not as restricted in your movements, which can be particularly advantageous in awkward positions or tight spaces.
  4. Keyhole Effect: The keyhole effect is another feature you’ll appreciate. It allows for complete single-pass penetration in thicker materials. This cuts down on the time it takes to complete a weld, as multiple passes are often not required.
  5. Faster Travel Speeds and Joint Alignment: Unlike some slower methods like Submerged Arc Welding (SAW), plasma welding allows for faster travel speeds. Also, if your joint alignment isn’t perfect, plasma welding is more forgiving, allowing for some variation in joint alignment without sacrificing weld quality.

What Are the Drawbacks?

However, as with anything, plasma welding comes with its own set of challenges:

  • Complexity and Skill Level: Plasma welding is not beginner-friendly. The process is complex and requires a higher level of skill compared to more traditional methods. The many variables involved—from gas flow to current settings—mean that there’s a steeper learning curve. This is not a “plug-and-play” process.
  • Equipment and Costs: The equipment required for plasma welding can be on the expensive side. It’s not just the initial cost; you also have to think about ongoing expenses like orifice replacements. And let’s not forget, the plasma control console and specialized nozzles add to this cost.
  • Maintenance Requirements: Unlike more robust systems like Carbon Arc Welding (CAW), the plasma torch is quite delicate. An accidental bump can result in costly repairs. Additionally, the small water-cooling passages in the equipment mean that you’ll have to invest in water filters and deionized water, adding another layer of maintenance to your tasks.

Common Uses and Limitations

Where Is Plasma Welding Used?

From pressure vessels to aerospace components, the range of applications is extensive. The process has even found its way into the medical field for the production of surgical instruments and implants.

The capacity to weld a variety of metals, including exotic ones like titanium alloys, makes it highly versatile.

Any Limitations?

Though it’s a powerful technique, plasma welding does come with some caveats. The torch is more delicate compared to more rugged welding systems.

Plus, the water-cooling passages are small, requiring specialized maintenance, such as the use of water filters and deionized water.


By now, you should have a comprehensive understanding of plasma welding.

From its unique characteristics to its range of applications, this method offers distinct advantages that make it worth considering for your welding projects.

While it may require specialized knowledge and a bit more investment upfront, the benefits are substantial.

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Marcus Colson
Marcus Colson

Welding is more than a hobby for me - it's a passion. The art of fusing metal together to create something new and functional never gets old. From intricate sculptures to sturdy structures, I love the endless possibilities that welding offers.

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