Plasma mig welding

Abstract

Methods and apparatuses for plasma MIG welding or TIG MIG welding are disclosed. They include a plasma or TIG torch for following along a weld path by a MIG torch (or the order may be reversed). A constant distance may be maintained between the torches, and the angle of the torches, relative to the workpiece, may vary. The MIG process is performed EP or EN in various embodiments.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:  
     
         1 . A method of plasma MIG welding comprising: 
 creating a plasma arc between a plasma torch and at least one workpiece;    providing relative movement of the plasma arc along a weld path;    creating a MIG arc between a MIG torch and the at least one workpiece;    providing movement of the MIG arc relative to the at least one workpiece along the weld path; and    wherein the MIG arc follows the plasma arc along the weld path.    
     
     
         2 . The method of  claim 1 , further comprising maintaining a constant distance between the plasma torch and the MIG torch.  
     
     
         3 . The method of  claim 1 , wherein the angle of the plasma arc is between +10 degrees and −10° degrees, where 0 degrees is perpendicular.  
     
     
         4 . The method of  claim 3 , wherein the angle of the plasma arc is between perpendicular and +5 degrees, wherein +5 degrees is the plasma arc angled toward the MIG arc.  
     
     
         5 . The method of  claim 3 , wherein the angle of the MIG arc is between +10 degrees and −45° degrees, wherein −45 degrees is the MIG arc angled toward the plasma arc.  
     
     
         6 . The method of  claim 4 , wherein the angle of the plasma arc is between 0 degrees and −30 degrees, wherein −30 degrees is the MIG arc angled toward the plasma arc.  
     
     
         7 . The method of  claim 1 , wherein the distance between the plasma torch and the MIG torch is greater for faster movement along weld path.  
     
     
         8 . The method of  claim 1 , wherein the MIG process is EN.  
     
     
         9 . The method of  claim 1 , wherein the MIG process is EP.  
     
     
         10 . A system of plasma MIG welding comprising: 
 a plasma torch;    a MIG torch; and    wherein the MIG torch and the plasma torch are mounted such that they are a fixed distance from one another.    
     
     
         11 . The system of  claim 10 , wherein the plasma torch is mounted such that the angle of the plasma torch relative to a workpiece is between +10 degree and 10° degrees, where 0 degrees is perpendicular.  
     
     
         12 . The system of  claim 11 , wherein the plasma torch is mounted such that the angle of the plasma torch relative to the workpiece is between perpendicular and +5 degrees, wherein +5 degrees is the plasma torch angled toward the MIG torch.  
     
     
         13 . The system of  claim 11 , wherein the MIG torch is mounted such that the angle of the MIG arc relative to the workpiece is between +10 degrees and −45° degrees, wherein −45 degrees is the MIG torch angled toward the plasma torch.  
     
     
         14 . The system of  claim 12 , wherein the angle of the plasma torch relative to the workpiece is between 0 degrees and −30 degrees, wherein −30 degrees is the MIG torch angled toward the plasma torch.  
     
     
         15 . The system of  claim 10 , wherein the MIG torch has an EN input.  
     
     
         16 . The system of  claim 10 , wherein the MIG torch has an EP input.  
     
     
         17 . A system of plasma MIG welding comprising: 
 means for creating a plasma arc between a plasma torch and at least one workpiece;    plasma movement means for providing relative movement of the plasma arc along a weld path, connected to the plasma torch;    means for creating a MIG arc between a MIG torch and the at least one workpiece; and    means for providing movement of the MIG arc relative to the at least one workpiece along the weld path, connected to the MIG torch and the plasma and connected to the plasma movement means, whereby the MIG arc follows the plasma arc along the weld path.    
     
     
         18 . The system of  claim 17 , further comprising means for maintaining a constant distance between the plasma torch and the MIG torch, connected to the MIG torch and the plasma torch.  
     
     
         19 . The system of  claim 17 , wherein the angle of the plasma torch relative to the workpiece is between +10 degrees and −10° degrees, where 0 degrees is perpendicular.  
     
     
         20 . The system of  claim 19 , wherein the angle of the plasma torch relative to the workpiece is between perpendicular and +5 degrees, wherein 5 degrees is the plasma arc angled toward the MIG torch.  
     
     
         21 . The system of  claim 19 , wherein the angle of the MIG torch relative to the workpiece is between +10 degrees and −45° degrees, wherein −45 degrees is the MIG torch angled toward the plasma torch.  
     
     
         22 . The system of  claim 20 , wherein the angle of the plasma torch relative to the workpiece is between 0 degrees and −30 degrees, wherein −30 degrees is the MIG torch angled toward the plasma torch.  
     
     
         23 . The system of  claim 17 , wherein the means for creating a MIG arc includes means for creating an EN arc.  
     
     
         24 . The system of  claim 17 , wherein the means for creating a MIG arc including means for creating an EP arc.  
     
     
         25 . A system of plasma MIG welding comprising: 
 a plasma torch;    a MIG torch; and    means for mounting the MIG torch and the plasma torch a fixed distance from one another.    
     
     
         26 . A system for plasma MIG welding comprising: 
 at least one power source having 
 a plasma power output,  
 a MIG power output, and  
 a control input; and  
   a controller operatively connected to the control input.    
     
     
         27 . The system of  claim 26 , wherein the at least one power source further comprises at least one plasma power source connected to the plasma power output, and a MIG power source connected to the MIG power output.  
     
     
         28 . The system of  claim 27 , wherein the controller comprises a plasma controller connected to a control input on the plasma power source and a MIG controller connected to a control input on the MIG power source.  
     
     
         29 . The system of  claim 28 , further comprising a plasma torch connected to the plasma power output and a MIG torch connected to the MIG power output.  
     
     
         30 . The system of  claim 29 , wherein the plasma torch and the MIG torch are mounted to one another.  
     
     
         31 . A system for plasma MIG welding comprising: 
 power means for providing a plasma power output and a MIG power output; and    control means for controlling the power means, operatively connected to the power means.    
     
     
         32 . A product formed by the process of plasma MIG welding a plurality of work pieces, wherein at least one of the plurality is comprised of galvanized steel.  
     
     
         33 . The process of  claim 30  wherein the galvanized steel is G-60 galvanized steel.  
     
     
         34 . The process of  claim 30  wherein the galvanized steel is G-90 galvanized steel.  
     
     
         35 . A method of TIG MIG welding comprising: 
 creating a TIG arc between a TIG torch and at least one workpiece;    providing relative movement of the TIG arc along a weld path;    creating a MIG arc between a MIG torch and the at least one workpiece;    providing movement of the MIG arc relative to the at least one workpiece along the weld path; and    wherein the MIG arc follows the TIG arc along the weld path.    
     
     
         36 . The method of  claim 35 , wherein the angle of the TIG arc is between perpendicular and +5 degrees, wherein +5 degrees is the TIG arc angled toward the MIG arc.  
     
     
         37 . The method of  claim 36 , wherein the angle of the TIG arc is between 0 degrees and −30 degrees, wherein 30 degrees is the MIG arc angled toward the TIG arc.  
     
     
         38 . A system of TIG MIG welding comprising: 
 a TIG torch;    a MIG torch; and    wherein the MIG torch and the TIG torch are mounted such that they are a fixed distance from one another.    
     
     
         39 . A system of TIG MIG welding comprising: 
 means for creating a TIG arc between a TIG torch and at least one workpiece;    TIG movement means for providing relative movement of the TIG arc along a weld path, connected to the TIG torch;    means for creating a MIG arc between a MIG torch and the at least one workpiece; and    means for providing movement of the MIG arc relative to the at least one workpiece along the weld path, connected to the MIG torch and the TIG and connected to the TIG movement means, whereby the MIG arc follows the TIG arc along the weld path.    
     
     
         40 . The system of  claim 39 , further comprising means for maintaining a constant distance between the TIG torch and the MIG torch, connected to the MIG torch and the TIG torch.  
     
     
         41 . A system of TIG MIG welding comprising: 
 a TIG torch;    a MIG torch; and    means for mounting the MIG torch and the TIG torch a fixed distance from one another.    
     
     
         42 . A system for TIG MIG welding comprising: 
 at least one power source having 
 a TIG power output,  
 a MIG power output, and  
 a control input; and  
   a controller operatively connected to the control input.    
     
     
         43 . The system of  claim 42 , wherein the at least one power source further comprises at least one TIG power source connected to the TIG power output, and a MIG power source connected to the MIG power output.  
     
     
         44 . The system of  claim 43 , wherein the controller comprises a TIG controller connected to a control input on the TIG power source and a MIG controller connected. to a control input on the MIG power source.  
     
     
         45 . The system of  claim 42 , wherein the at least one power source further comprises at least one TIG power source connected to the TIG power output, and a MIG power source connected to provide the MIG power output as EN.  
     
     
         46 . The system of  claim 42 , wherein the at least one power source further comprises at least one TIG power source connected to the TIG power output, and a MIG power source connected to provide the MIG power output as EP.  
     
     
         47 . A product formed by the process of TIG MIG welding a plurality of work pieces, wherein at least one of the plurality is comprised of galvanized steel.