This post will be a compilation of frequently asked questions (FAQ's) as well as a source of information. If you feel something should be added, PM either myself or Doctor Cortez and we'll be sure to add it. Keep in mind this is just the beginning.
Plasma Cutter
A plasma cutter can pass through metals with little or no resistance thanks to the unique properties of plasma. So what is plasma?
There are four states of matter in the world. Most things we deal with in our daily lives are in the form of solids, liquids, or gases. These states are divided based on the way that molecules behave within each one. Take water as an example:
As a solid, water takes the form of ice. Ice is made up of neutrally charged atoms arranged in a hexagonal pattern that forms a solid. Because the molecules stay fairly still relative to each other, they form a solid -- something that holds its shape.
As a liquid, water takes its drinkable form. The molecules are still bound to each other, but they move relative to each other at slow speeds. The liquid has a fixed volume, but no constant shape. It changes shape to fit whatever container you put it in.
As a gas, water takes the form of steam. In steam, molecules move around at high speeds, independently of each other. Because the molecules are not bound to each other, a gas has no fixed shape or fixed volume.
The amount of heat (which translates to the amount of energy) applied to water molecules determines their behavior and therefore their state. Simply put, more heat (more energy) excites molecules to the point that they break free of bonds that bind them together. With minimal heat, the molecules are tightly bound, and you get a solid. With more heat, the molecules escape the rigid bonds, and you get a liquid. With even more heat, the molecules escape the loose bonds, and you get a gas.
If you boost a gas to extremely high temperatures, you get plasma. The energy begins to break apart the gas molecules, and the atoms begin to split. Normal atoms are made up of protons and neutrons in the nucleus (see How Atoms Work), surrounded by a cloud of electrons. In plasma, the electrons separate from the nucleus. Once the energy of heat releases the electrons from the atom, the electrons begin to move around quickly. The electrons are negatively charged, and they leave behind their positively charged nuclei. These positively charged nuclei are known as ions.
When the fast-moving electrons collide with other electrons and ions, they release vast amounts of energy. This energy is what gives plasma its unique status and unbelievable cutting power. (howstuffworks.com)
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The TIG (Tungsten Inert Gas) welding process (also known as gas tungsten arc welding, GTAW, or HELIARC, a trade name of Linde) generates heat from an electric arc maintained between a non consumable tungsten electrode and the part being welded. This process was developed for the aircraft industry back in the early '40s. TIG may be used without the addition of a filler metal or a separate wire filler metal can be added into the puddle when additional material is required, much like the process in oxy-acetylene welding. The puddle, the tungsten electrode and the filler rod are protected from atmosphere by a shield of inert gas to prevent rapid oxidation of the weld and surrounding metal. Argon is the most widely utilized gas. Because the gas shield does not produce the slag that normally is created by flux, the danger of slag inclusion in the weld metal is eliminated. Also, due to the slow speed of the TIG process, gases and other impurities escape to the surface of the puddle before solidification occurs, eliminating pockets called "Porosity" common in weld processes that employ gas shielding but have greater travel speeds than the TIG process. TIG also produces a welding heat is that is confined between the weld and base metal at the point of fusion and produces a narrow heat affected zone. This reduces stress, cracking and distortion in the finished weld. Spatter is not produced by this process, leaving the weld and surrounding metal clean. Because of the lack of spatter and flux smoke, the TIG process allows the operator a clear view of the weld puddle. The torch body in most cases is small enough that the operator can hold it in the same manner as he would hold a pencil allowing easier manipulation. The power source is constant current, either AC, DC, or combination AC/DC. Type of metal determines which type is used. DC (direct current) is most normally used for TIG welding of stainless steels and mild and low alloy steels. AC (Alternating current) is used for TIG welding of aluminum. Surface oxidation is automatically removed by the action of the arc each time the electrode becomes positive, (60 times per. second). Because AC crosses over the zero volt point 120 times per second (once going positive and once going negative each cycle), the arc shuts off 120 times per second. To keep the arc going when using AC, a high frequency "arc stabilizer" is used. The high frequency also allows the start of an arc in DC mode without having to "strike" an arc, thereby reducing the possibility of tungsten contamination. If the electrode accidentally touches the weld pool, it becomes contaminated and must be cleaned immediately to prevent weld contamination. TIG requires an extremely clean surface to weld successfully and is a fairly slow operation. On the plus side, TIG produces high quality work and does not generate slag or spatter. The welder can adjust the heat input while welding by using foot or hand amperage controls. MIG (Metal Inert Gas), also referred to as wire feed welding, utilizes a consumable arc. The process generates heat from an electric arc maintained between a consumable wire feed electrode and the part being welded. This process produces spatter making it difficult for the operator to see the weld and causing damage to nearby surfaces and objects from the hot particles thrown off. Flux cored "gasless" welders produce smoke from the flux, and pose a cleanup problem. Because of the higher welding speeds of the MIG process, the chance of producing porosity is higher. A common mistake with novice welders utilizing the MIG process is the possibility of producing a good looking weld with little penetration. A MIG can produce an arc into the puddle, allowing one to create a nice looking weld while the base metal underneath is not being properly melted. This cannot be detected before failure without either destructive or non-destructive testing. In the TIG process, the base metal is melted to produce a puddle before any filler is introduced into the weld. This allows the operator to see the penetration during the welding process. Another drawback in MIG welding in restoration of automobiles is the workability of the weld. The wire used in MIG cools harder than in TIG welding, making it harder to hammer and dolly the weld afterwards. Because MIG welding uses a constant fed wire to produce the arc, some buildup of material usually occurs that has to be ground off. This also generates heat in the panel that can cause warpage. With TIG, filler is only added when needed, and the thickness of the filler can be changed by picking up a different size rod. This reduces post weld finishing. While TIG welding requires greater skill, the results are far better than other welding methods. Welders of both types are available from many sources, such as Eastwood, Daytona Mig, and Professional sources such as Miller Electric. A source that I have found to be particularly helpful and has excellent prices is RRAM Sales. If you are looking for a welder, I recommend staying away from Flux cored units. They are messy and many do not have the power required to do most welding you will get into. Small 110 volt welders are available that will do a good job with practice, but go with gas for MIG (MIG by definition is metal INERT GAS, not flux) Flux cored units are advertised as "wire feed", Don't assume that they are MIG welders. If you are looking for a TIG, there are also several nice small units available, but consider it only if it has "high frequency" and AC if you don't want to mess with striking an arc and there is a remote possibility that you may want to weld Aluminum someday. SAFETY NOTICE Be careful when welding parts that are possibly plated! Welding of these materials is not for the average person, as special precautions must be taken! TOXIC FUMEScan be given off when welding various platings that can cause serious medical problems orDEATH. For an update of this problem and to visit a company interested in your safety, see Borgeson Universal Co. Any welding of suspension, steering, or safety critical component should be done by a qualified welder. Any weld that could cause an accident if it failed should be inspected by non-destructive means. Most local machine shops can perform magnaflux inspections at a reasonable price. Don't take chances - if in doubt, ask a professional.
CARBON FIBRE Carbon fibre is the most technological material available. It consists of a fabric of fibres immersed in a resin and then solidified. Mechanically, it can be unbeatable.
It is a synthetic fabric made up of fibres derived from petroleum and processed at high temperature. Advanced composite materials in carbon fibre are obtained by combining two or more components. Of all existing composite materials, the fibrous ones have the highest structural properties.
The unidirectional or woven fibres, pre-impregnated in resin, are placed in moulds along the load lines indicated by mathematical calculations, so as to obtain a component which meets specific technical and structural requirements. The process is completed with the hardening of the resin, which is achieved by “baking” in an autoclave to produce the final solid material.
Carbon fibre is a polymer which is a form of graphite. Graphite is one of the states of pure carbon. In graphite, the carbon atoms are disposed in aromatic hexagonal rings bonded to each other to form large planes. Their appearance is like that of metal netting.
Carbon fibres are a form of graphite in which these sheets are long and narrow; imagine that they are ribbons of graphite. These ribbons group together readily in bundles to form fibres, hence the name carbon fibre.
The fibres are not normally used alone, but are used to reinforce materials such as epoxy resins or other thermosetting materials. The resulting reinforced materials are known as composites because they contain more than one component.
Composites reinforced with carbon fibre have a very favourable strength to weight ratio. They are often stronger than steel but much lighter. For this reason, they are used to replace metals in many applications, such as aircraft, the Space Shuttle, race car bodies, tennis rackets and golf clubs.
"Carbon fibre" is a composite material in which the carbon fibre constitutes the effective reinforcement, enclosed in polymer resins of different types. The fibre performs the work of resisting stresses, while the resins act as a binding agent, i.e. they keep the fibres in their original position. This is because, while traditional metals respond identically to stresses applied in different directions, carbon fibre only resists stresses applied along the length of the fibres. It therefore follows that the right direction of the fibres is the cornerstone of a correctly built carbon chassis, which means that technology and experience are primary considerations.
It is true that carbon can be used to make all kinds of items. It is even used to make fishing rods and tennis rackets. But the chassis and suspension arms of Formula 1 cars are also made of carbon fibre, and for these applications you can't be casual with regard to strength and solidity. Everything depends on how the carbon is processed. The carbon thread itself has identical properties in every fibre, but it is woven differently so as to ensure adequate strength according to the direction of application of the stress. The secret of carbon fibre lies in the layering of its "skins": each layer can have different properties and is disposed along the stress lines to which the finished product will be subject.
Technique, creativity and precision are essential requirements for producing a hi-tech chassis. Along the entire path from idea to finished product, our chief pre-occupation is to strike the ideal balance between strength and weight.
To achieve our goal, we have developed a system of processing which makes best use of all the advantages of carbon fibre. The products made using these fabrics, impregnated with epoxy resins, bind the carbon atoms, and incorporate incredibly high strength and elasticity.
A monocoque structure in carbon fibre is currently the best material available for the construction of chassis, thanks to its high strength and low weight.
Properties:
• High specific strength • High tensile strength • High specific modulus of elasticity • Low weight
