Plasma Arc Welding (PAW - Plasma Arc Welding) is a more advanced and refined welding process than TIG (Tungsten Arc Gas Welding). It enables ultra-deep penetration, micro-welding, and even plays a key role in the aerospace and nuclear industries! You may think you know all about PAW, but these cold facts may be eye-opening!
Is PAW actually an “upgraded” version of TIG?
Many people think of a PAW as “TIG with a nozzle,” but in reality, a PAW is far more powerful than a TIG:
| Comparison items | PAW (Plasma Arc Welding) | TIG (Tungsten Arc Welding) |
| Arc contraction | More concentrated energy due to nozzle constraints | Arc dispersion, less concentrated energy than PAW |
| Depth of penetration | Up to 10mm (single pass) | Typically ≤5mm |
| Welding speed | Fast (30%-50% faster than TIG) | Slower |
| Automation | Easily integrated robot | Mainly for manual welding |
| Range of application | From micron welding to thick plate welding | Mainly for thin plate welding |
PAW can be used perfectly on both ultra-thin (0.1mm) and ultra-thick (10mm) materials, whereas TIG does not have such a large span!
How can a PAW do “micro-welding”?
• PAW can weld extremely thin materials under 0.05mm, such as electronic components, sensors, and medical devices, with ultra-low currents (less than 1A)!
• NASA uses PAW to weld the micro-thrusters (combustion chambers smaller than a match head) of satellites!
Can PAW also weld “unweldable” metals?
While many welding methods struggle with high melting point metals (e.g., tungsten, molybdenum), reactive metals (e.g., titanium, zirconium), and ultra-thin aluminum alloys, PAW can do it with ease!
- Welding titanium alloys (aerospace, nuclear)
- Welding stainless steel sheet (food, pharmaceutical equipment).
- Welding aluminum foil (batteries, electronics).
The high energy density and stability of the PAW makes it the first choice for welding difficult metals!
Did you know that PAWs can also be “keyhole welded”?
What is keyhole welding?
Laser (LBW) and Electron Beam (EBW) welding creates a “keyhole” that can be used to weld thick plates with deep fusion penetration, and PAWs can do the same!
The plasma nozzle acts like a spray gun, concentrating the arc beam into a powerful plasma stream that melts through the metal!
• Welding through 10mm thick steel in one pass? No problem!
• Cheaper than laser welding, but with similar penetration!
Therefore, PAW is a cost-effective choice for automated welding of thick stainless steel and nickel-based alloys!
Can PAWs weld “through the air”?
While conventional welding methods (TIG/MIG) require the electrode to be in direct contact with the workpiece, the PAW can “strike from a distance”!
The PAW's Transfer Arc mode creates a powerful plasma stream between the torch and the workpiece, melting the metal without electrode contact!
This is extremely useful when welding hard-to-reach parts (e.g., turbine blades, sealed cavities).
PAW can also do cuts that are finer than a plasma cutter?
PAW not only weld, they also fine cut, with even greater precision than regular plasma cutting (PAC)!
PAW cutting applications:
- Ultra-fine cutting of titanium and aluminum alloys
- Aircraft turbine blade repair
- Surgical blades, precision medical device manufacturing
It is cheaper than laser cutting and finer than normal plasma cutting.
PAW is an aerospace grade welding technology!
NASA has been using PAW to weld fuel lines on spacecraft since the 1960s!
Many of the key components of the nuclear reactors on U.S. aircraft carriers are also PAW welded!
The titanium skin of the Boeing 787 airplane is PAW welded to increase strength and reduce weight!
PAW welding is a true “aerospace grade” process, capable of welding extremely demanding materials!
Summary
Plasma Arc Welding (PAW) is not just a “beefed up” version of TIG, it is in fact a high-end welding technology that is able to maneuver between ultra-thin and ultra-thick materials, and can also be used for precision micro-welding, deep-melt welding, non-contact welding, and can even replace some of the laser welding!
- Welds “unweldable” metals (titanium, zirconium, aluminum foil, etc.).
- Keyhole welding (10mm deep fusion welding in a single pass).
- Fine cutting, more accurate than normal plasma cutting.
- Can be used in aerospace, nuclear power, military and other high-end manufacturing.
Do you still think that PAW is just “Advanced TIG”? It's actually a low-profile but powerful welding technology of the future!
If you'd like to learn about a specific application for PAW, such as automated welding, robotic welding, or an industry-specific application, contact us!
Post time: Apr-03-2025