How to Weld Powdered Metal
Powder welding is among the lesser-known welding processes as it is a less common practice. Sometimes the technique is used to deposit iron-based alloy powder and flux from a hopper attached to an oxyacetylene torch onto base metal where it builds up a thin layer of metal. More often powder welding is done with computer numeric controlled or CNC plasma welding machines. The machine needs to be programmed and setup, then it does all the work of rebuilding worn parts or building up specialty alloys on heavy-wear areas of parts.
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Instructions
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Program the CNC machine to the weld pattern, heat and speed that meets your application. CNC machine have various control interfaces, but they will all allow you to adjust the same factors you must control when hand-welding -- speed, heat and and the motion of the arc. Select a powdered alloy that matches the material you are welding or choose a modified alloy to augment the properties of your base metal.
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Set up your base metal in the CNC plasma welder, positioning the starting point of the CNC welding tip to the point on the metal where the the bead should begin.
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Clean your base metal so it is free of any oil, grease or dirt.
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Load the alloy and flux powder into your CNC welder's hopper.
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Press the start button on your CNC program and allow it to execute, observing carefully during the welding process.
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Adjust your CNC program or the base metal based on an evaluation of the results. So, for example, if the welded bead wanders an eighth of an inch off, you can adjust the CNC coordinates for the next piece or mount the next piece so that the weld will align properly.
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Tips & Warnings
Wear appropriate safety gear to prevent slag-burns and a welding helmet to protect your eyes.
While plasma is a hotter process than other kinds of welding, it is just as important to prep and clean our base meal before you begin.
References
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