[1] Do you see the usage of your welding equipment in manufacturing and repairing of different vehicles, ships, aircrafts?

[2] Can You use your experience in colleges and technical schools for the youth teaching and fascinating?

[3] Have You an experience of quality control or expertise in manufacturing of tubes, tubes lines and pipe gas stations welded by conventional methods?

[4] How to use your inventions for edge welded bellows producing in order to increase their working resources?

[5] Tell, please, in more details about your equipment usage for moulds and stamps repair.

[6] What equipment you have in your possession for different works fulfilment?

[7] What are the real technological possibilities of your AMC-1 welder now?

[8] Please give some examples, showing exclusive possibilities of the proposed new sets as compared with similar sets or with the cheap gas brazing units.

[9] Why you prefer microplasma or plasma methods among other methods for thin (less than 3 mm thick) metal joining?

[10] Do you know such cheap and simple welding-brazing equipment which may be used for thin structures manufacturing and repair without using of gas cylinders that usially have big dimensions and weight? And why you prefer your equipment?

[1] Do you see the usage of your equipment in manufacturing and repairing of different vehicles, ships, aircrafts ?

Yes, of course. For example any thin - walled transport device has ribs and so-called elements of rigidity situated inside of welded structures. For their joining the contact (resistance) spot machines are usually used, and sometimes these machines have to be rather complicated and need very big electrical power. Sometimes the structures which have to be welded are impossible to insert to the working zone of the mentioned above machines or these structures do not permit to apply-load to them pressing forces. Our equipment permits to make plasma spot welds without any problems, giving spots with good appearance without typical for contact welding obvious deepening in the spot weld area. Plasma spot welding energy expenses are 2-3 times lower than during resistance spot welding, although the time of plasma welding is essential longer.

At the same time producing of accurate welding spots may be used for micro cracks elimination without appreciable post cleaning.

As compared with argon welding plasma gives less deformations what is very important for cars repair. Last procedure may be successfully made while combination of our cheap, safe and simple sets with the German "Cu S13" (company EWM) brazing wire. If to use this wire with the minimum diameter, it may be possible to make very accurate repair welding-brazing of extra thin cars (and not only cars) components, like thin-walled bodies, boxes, doors, reservoirs, etc. We are sure that it will be preferable in future, especially while using our original universal plasma head which has special channels for a filler material supplying (please, see the present torches and heads rubric). This head may be also successfully used together with blocked plasma set and spot plasma welder.
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[2] Can You use your experience in colleges and technical schools for the youth teaching and fascinating?

Yes, we can. Students of many educational organizations may use such experience plus the proposed sets:

• a) directly for precision structures producing and repair
• b) with the aims of studying plasma processes, electricity, physics, electronics, etc.

For instance, new set may be used - as so-called "Plasma Master", or "Plasma Helper", - for welding and repairing of visual aids, hand-made articles, different units, gauges, control instrument and sensors, various real and artificial goods for industries, medicine, studying processes and home appliances. And it can be operated by personnel which is rather far of welding specialization.

However, usage of the proposed sets is especially probable as one learns of low-temperature (up to 30,000 degrees) generated plasma, the capabilities of which, within educational programs and scientific research , far from exhausted. Moreover, often plasma physical-chemical processes with the usage of varies protective gases and inserted into the plasma substances will allow creative workers to discover new fields in a multitude of novel processes, using totally unexpected appliances of the plasma - the so-called forth state of the substance. Naturally, this may enrich the process of educating talented students and, the possibility is not excluded, that with their participation new inventions would be made or even discoveries in the branch of low-temperature plasma.

By the way, the author of this site has a large experience in work with pupils-children and various students of several courses, including international - in the frame of UNIDO. So, it is possible to participate in diffrent educational programs.
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[3] Have You an experience of quality control or expertise in manufacturing of tubes, tubes lines and pipe gas stations welded by conventional methods?

Yes, I have. Durng a few years I am worked as a welding engineer at the CHEMO AHARON COMPANY which is successfully involved to building of pipe gas stations and gas pipe lines for the Israeli Electrical Company in order to supply it by gas. All these works are produced under international supervision, and I participated in quality control of preparatory procedures, welding processes and inspection of welds, manufactured by coated electrodes, by MAG and TIG welding methods (according to international standards: ISO 9001 and documents NEN 3650-2003, ASME IX code - 2004).
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[4] How to use your inventions for edge welded bellows producing in order to increase their working resources?

Please, pay attention to our present rubric unique innovations (the top picture and the explanation to it). The plain of two edges contact of the usual-traditional (left) edge weld configuration has a role as sharp knife which is provocative of this weld destruction while the stretch (or, especially, cyclic or dynamic) loads action. A radius shape of the edge weld root, as it is shown in the proposed configuration case (right), improved such weld working properties.

At the picture N.1 - FOILS WELDS TYPICAL STRUCTURE of the previous site www.pogrebis-temp.com/technologies.html you have to see more attentively the down welds composition. Its left part shows 6 top examples of edge welds - made with gaps in 15-120% of edge thickness. The opposite - right - side shows usual- traditional welds made without gaps, as well as welds examples which are showed at the top of the mentioned picture. Due to the presence of the marked before zones of concentration of tension, the strength (on the rupture - break) of such traditional edge welds (of metals 0,05 - 0,5 mm thick) is no more than 70-85 % of the strength of the base material - even under static load. Our welds "modernization" permits to increase their static strength on 10-12 %.

Without the doubt it is clear that , if to use the proposed root weld configuration in edge welded bellows, their working resources (life) will increase very essentially.

Another way to increase such bellows quality is to use impulse optimal parameters of their welding. A lot ago, working with the aircraft company Lavochkin-Soiuz, it was found that traditional edge welds, produced in continious mode, having an excellent shining-mirror appearance, give the mentioned above strength on the static rupture less than the same welds, but welded in the optimal impulse mode, though their appearance was not so beautiful as of welds made in continious mode. The matter was that very often during welding in continious mode an axis dendrite crystallite is growing, and cracks are usually spreading along it. On the contrary, such spreading makes much more difficult while the impulse optimal mode usage because it gives the so-called toothed front of crystallization of many-many spots which put together the weld during its fulfilment in impulse mode. The mentioned shape of crystallization (due to the specific interlacing of the composing the weld spots) brakes the cracks easy spreading - because they may free move only in the space of single poin-spot weld and slow down before each "teeth" of crystallization in the area of the next spot weld. Here we have to remind once more that in impulse mode the weld consists of a lot of the similar and rather small spots- points (please, see our picture N.1 - Some peculiarities and possibilities of pulse welding - at our previous site www.pogrebis-temp.com/unique.html). So, the continuation of cracks spreading (from a point to a point) needs the additional and essential energetic expanses that, naturally, increases the weld strength, if it made in an optimal impulse-pulse mode.
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[5] Tell, please, in more details about your equipment usage for moulds and stamps repair.

There is information about using laser and argon welding equipment for these purposes
( www.pma-magazine.com/articles/2002/march/06 ). We add our information basing on large experience of such works in Ukraine and the former USSR . As a result we obtained the such Table:

  Pulsed ND:YAG Laser CO2 laser and YAG laser Microplasma and and medium current plasma TIG (argon welding)
Type of deposition wire powder usual wire and powder wire wire
Area of application (Volume) small/medium medium / large medium medium / large
Size (minimum) of welding (mm) 0.2 - 0.8 0,6 - 1,2 < 3 0,5 - 5
Heat input in mould low medium medium high
Preheating required for high - hardness alloys no yes no/yes yes
Degree of automation semiautomatic fully automated manual manual
Investment, USD ($) 30,000 - 90,000 > 500,000 < 8,000 5.000 - 15,000

As we see, taking into consideration low price of the proposed set and its better regulation while work in a manual mode, it has an excellent perspective to be used for the moulds and stamps repairing (please, see our moulds, stamps and turbine blades repair).
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[6] What equipment you have in your possession for different works fulfilment?

We have practically:

• 1. Modular-Inventer AMC-1 Welder
• 2. the prototype of cheap, safe and simple sets (please, see also www.pogrebis-temp.com/last-projects.html, where this set is showed alone - the first picture, and then: the plasma torch, optical system, water-cooled, movable table, etc. - their photos you can see at the second and the third photos of the same site)
• 3. Special Rotator - with the hollow (tubular) spindle which may be used for circle welds fulfilment and - in some cases - for edge welded membrane and bellows structures manufacturing (or repair)- please, see our rubric other
• 4. OB-2322 Plasma Torch (for manual and mechanized processing)
• 5. Blocked Plasma Set
• 6. Spot Plasma Welder

Last two sets are based on DC-AC unit (with currents 30-160 A) for stick (electrode) welding that can be used on it's one. Of course, we have accessories for manul welding by coated electrodes, as well as gas cylinders and reducers for plasma and argon welding. For last method we have a standard manual torch. Also in our possession there are: two-channel and compact oscillographs, a lot of instrument, tools, elements of radio electronics (transistors, thyristors, switchers, relays, transformers, etc.), tungsten electrodes, some additional blocks and materials. As we suggest, it is possible to buy the developed by us Module for Straightforward Processing (please, see the present site rubric with the same name and the picture N.4 - Universal technological module for precision processes of treatment, especially for plasma processing - of www.pogrebis-temp.com/equipment.html). We began to make a model of device for microplasma spraying. So, we have a base for a welding and materials treatment laboratory, for a manufacturing division of a company or of a scintific-industrial-educational sub-unit of a college, university, etc.
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[7] What are the real technological possibilities of your AMC-1 welder now?

Now this set is not in a working position, and it needs tuning and adjusting that have to be made of the place of its future usage (we have the technical documentation of this set). The base parameters of our set allow to weld goods like plate heat exchangers (see, our rubric plate heat exchangers and www.pogrebis-temp.com/unique.html) with gaps and displacements of edges, essentially exceeding their width - without filler material usage. In order to use this set for microplasma welding of foils with thicknesses less than 0,1 mm it has to be re-adjusted for more short durations of impulses and pauses (which are known for us). As compared with new simple sets, this AMC-1 welder is not applied for brazing.
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[8] Please give some examples, showing exclusive possibilities of the proposed new sets as compared with similar sets or with the cheap gas brazing units.

We can give this information using the given below Table (based on our rubrics parts of machines and cars, braceletes and platinum jewelry, electric and electronic industries, transformers, engines, motors, other applications):

Users problems which may be made by new sets usage How it is making now Why our decision is better
1.Brazing of collector connections of electric engines armature By gas flame Much more quality and absence of post-cleaning
2.Brazing of thin-walled pipes in miniature heat-exchangers (made from copper alloys) and sometimes radiators (made from the same material) repairing By gas flame Absence of essential post-cleaning and form correction
3.Miniature brazing in space-tight conditions of jewelry production By gas flame Absence of probability of closely situated elements damage or hinges mobility violation
4.Making of original reliefs and surfaces, using local solder melting without noticeable deformation of a base material it is impossible It gives such exclusive possibility
5.Welding of glass-coated thermocouples and wires in enamel isolation with minimal damage of these coatings By gas flame It gives less isolation damages
By usual microplasma welding - with preliminary
wires cleaning from glass or isolation
It does not need pre-cleaning (in the majority cases)
6.Local heat-treatment of teeth and cutting edges of small mills, valves, precision
armature, etc. without electrical interaction with their surfaces
Because of small power of the non - transferred arc it is impossible Due to the big power of the non- transferred arc it became possible

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[9] Why you prefer microplasma or plasma methods among other methods for thin (less than 3 mm thick) metal joining?

The main comparative characteristics, or properties, of different joining methods valid for thin-walled structures manufacturing are gathered by us in the Table:

Comparative

Properties
Joining methods
Gas Tig Plasma Laser Electron beam Resistance spot High frequency
Level of universality high high high limited limited medium limited
Productivity low medium medium / high high high high very high
Energy expences low low low/medium high high high very high
Ecologycal problems yes not not yes not not yes
Materials properties limitation yes almost not almost not without high reflective capability without easy evaporating components except silver and copper yes
Assembling quality demand low low low/medium high high medium high
Hygeinic demand medium low medium high very high medium medium
Post-joining deformations large quite large medium very small very small small small
Operator's qualification high high low very high very high low high
Working room (place) dimensions medium small small medium medium / large medium / large medium / large
Working piece sizes and location every every every limited limited limited limited
Equipment cost very low low medium high high medium medium / high

We have not taken into consideration some specific methods - cold, ultrasonic, diffusion, by magnetic fields, etc. But it is clear that plasma methods may be more attractive in the majority cases because , as we see from the given Table, they have many obvious advantages. Among them there are saving of energy, time and human recourses. Last moment takes place due to possibilities to invite unqualified operators while new sets using (as compared with argon and beam sets).
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[10] Do you know such cheap and simple welding-brazing equipment which may be used for thin structures manufacturing and repair without using of gas cylinders that usially have big dimensions and weight? And why you prefer your equipment?

Yes, of course. In our rubric dental laboratories you can find the shown below Table which gives Main joining methods & equipment, applied to thin-walled structures, and their comperative properties:

View table

We can add that at the Moscow International Dental Forums ('Dental-Expo 2004', 14-17 Sept. 2004) the modern configuration of device that used water dissociation (LIGA-12, Saint-Petersburg) has been demonstrated. According to its passport, the "LIGA-12" has the following parameters: one fase, 220V, 50 hz, I max = 8A, W = 1,8 KVA, maximum gas flame temperature 2600 °C, dimensions (mm) 170x270x260, weight 12 kg. The maximum operated metal thicknesses may be up to 2 mm. The price of this device is currently $450. We do not know the price of the "Multiplaz-2500" Plasma Set, but it is known that this set had been awarded the Gold Gran Prize - the highest price of the 26th World Saloon in Geneva - as the best invention of 2002. The distinctive features of the Multiplaz-2500 are that it has a weight 6,5 kg, may be placed in a small shoulder bag and it uses as a shielding gas, as well as a cooling substance, steam-evaporations of water or its mixtures with spirit.

As we see from the given above Table, although the proposed new welding SETS are more expensive and not so compact as "Liga-12" and "Multiplaz-2500", they have more technological possibilities and less limitations from the point of view of their welding-brazing usage. In other words, new sets are more suitable for very thin metals welding and joining.
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