1. Super-MIG™ Combined Plasma-MIG Arc Technology and Equipment Manufactured by

2. SpaceForm’s Evolution
Delphi creates SpaceForm Inc.
Weldmation Creates Welding Solutions Inc. WSI)
SpaceForm has worldwide rights to the DRW technology
WSI Licenses SuperMig® from PLT
SpaceForm and Welding Solutions merge to form SpaceForm Welding Solutions Inc. to commercialize DRW and SuperMig Technologies

3. Process History 1969 - Philips Research Laboratories
Coaxial application with wire feed through plasma torch
1984- First plasma MIG system developed for welding zinc coated steels
Low power and slow travel speed application
Attempts at higher amperage levels and speeds resulted in process instability
Paton Welding Institute investigates the technology
1995 – PLT formed in Israel
Emphasis on Plasma Laser
PLT’s United States office started

4. Super-MIG™ SuperMig Hybrid Plasma/MIG Welding System
Integration with all standard robotic MIG welding systems
Consists of Three Components:
Interface, Torch, and Cleaning Station
Utilizes standard MIG power sources:
Lincoln, Miller, Fronius, Panasonic, OTC, etc…
Capable of operating in multiple welding process modes:
Plasma, Plasma/MIG

5. Process Basics The Plasma arc is started Keyhole may be established
MIG wire feed started, establishing the MIG arc.
Torch movement begins
Travel Direction

6. Process Interactions
DCEN
DCEP
Magnetic field interaction between the two arcs wants to force them apart
Without SuperMig Magnetic Shield
DCEN
DCEP
Magnetic Shield
With the introduction of an additional magnetic field the arcs can be brought together.
This field is adjustable
Stability of the anode spot of the plasma arc is increased
With SuperMig Magnetic Shield

7. Process Variables
Preheating and depression of metal surface allows for deeper penetration without a full keyhole
Heat from plasma torch adds to melting of MIG wire
Higher deposition rates
More consistent arc lengths
Reduced spatter
Plasma power levels
High amperage - Penetration
Low amperage – Part cleaning / Coating removal
Magnetic shield levels
High levels – Narrows arcs / Increased penetration
Low level – Wider arcs / Preheating

8. HAZ Comparison SuperMIG MIG
1400°
1400°
1200°
1000°
800°
600°
1400°
1400°
1200°
1200°
1200°
1000°
1000°
1000°
800°
800°
800°
600°
600°
600°
Travel speed - 90 in/min
Travel speed - 50 in/min
Travel speeds chosen to obtain equal penetration
Temperatures (oC)

9. Travel Speed Comparison
Welding Speed Per Inch
Welding Metal Thickness

10. SuperMig Slow Motion Photography

11. Heavy Section Development
Material
Travel Speed (ipm)
Plasma Current (A)
Mig Current (A)
300 series Stainless Steel
16.6
340
536

12. Robotic Installation SuperMIG Torch Welding Power Supply Interface
Cleaning Station

13. System Component Description
Interface
Compatible with all standard robot controllers
Includes an integrated Unitronics PLC
Capable of storing multiple welding programs
Gas flow monitor allows gas mixture adjustment
Plasma power source
Pump and reservoir for the torch cooling system

14. System Component Description
Torch
Hard Bodied Torch
Water Cooled
Electrically Isolated
Wire diameters
.035”,.045”, and .052”
Torch
Plasma
amps
MIG
STD
200
350
HCC
500 HD
650
Under development
- Aluminum
- Hardfacing

15. System Component Description
Torch Cleaning Unit
Step 1
Gas Shield Nozzle is
removed and cleaned
with spinning wire
brush
Fully Automatic via the robot program
Four Step Process accomplished in
8 seconds
Cleaning Frequency is based upon welding application
Step 2
Torch moves to forward
position where spinning
blades clean MIG and
Plasma tips
Step 3
Torch moves back to first
position where Gas
Shielding Nozzle is
reattached
Step 4
Torch Nozzle is sprayed
with a small amount of
anti-spatter liquid

16. Benefits compared to Conventional MIG
Travel Speed
Increased Welding Speed (2 times over std. MIG)
Quality
Weld Penetration
Removal of coatings or contaminates
Narrow Heat Affected Zone (HAZ)
Cost
Reduced Edge Preparation
Part Cleaning
Increased Production
Reduced Capital Equipment/Tooling

17. Contact Information
Alain Piette, President
SpaceForm Welding Solutions Inc.
(USA)
1001 W. Thirteen Mile Road
Madison Heights, MI (USA)
Brian Finnigan, Manager Advanced Welding Technologies
SpaceForm Welding Solutions Inc.
(USA)
1001 W. Thirteen Mile Road
Madison Heights, MI (USA)