Controlled atmosphere welding system
The controlled atmosphere welding system, model IRS 2000.01, is designed for performing welding operations on components made of chemically active alloys in an inert environment to obtain welds whose quality is difficult to achieve under conventional welding conditions.
The chamber can withstand a vacuum of at least 5×10-5 mmHg. Pumping speed into the vacuum chamber is 0.7 L·Pa/s, evacuation time to working vacuum is 30 minutes, and gas consumption per cycle is 8 m3.
The system includes a three-axis manipulator that allows for the most convenient positioning of the workpiece.
- Door limit switch
- Clamping cylinder
- Dial pressure gauge
- Gloves
- Reducer with motor
- Door trolley guide
- Pressure maintenance pump
- Uninterruptible power supply (UPS)
- Control unit
- High vacuum valve cylinder
- Pre-evacuation valve
- Fore-vacuum valve
- Locking valve
- Rotary pump
- Roots pump
- Fore-vacuum valve
- Pressure equalizer valve for glove port
- Pressure equalizer valve for glove port
- Power cable chain
- Door trolley
- Pneumatic door clamp
- Port viewing window
- Pneumatic cylinder
- High vacuum valve
System Components
Main Chamber
Dimensions L/W/H — 1700/1600/2300 mm
Chamber volume — 6.25 m3
Maximum vacuum — 5×10-5 mmHg
Pumping speed — 0.7 L·Pa/s
Evacuation time to working vacuum — 30 min
Gas consumption per cycle — 8 m3
Voltage — 3×380 V
Frequency — 50 Hz
Max power consumption — 66 kVA
Environment — Argon
Diffusion Pump
Air pumping speed — 20,000 L/s
Ultimate residual pressure — 6.7×10-8 mbar
Operating range — 1.0×10-2 to 6.7×10-8 mbar
Cooling water flow (at 6 bar) — 6 L/min
Weight — 272 kg
Roots Booster Pump
Nominal pumping speed — 2050 m3/h
Ultimate partial residual pressure — 8×10-3 mbar
Leak rate — 5×10-4 L/s
Noise level — <80 dB
Cooling water flow — 2 L/min
Motor power — 7.5 kW
Weight — 406 kg
Industrial Chiller
Cooling capacity — 20 kW
Pump operating pressure — 0.1–0.5 MPa
Supply voltage — 380±10% V
Frequency — 50 Hz
Number of phases — 3
Ambient temperature — 10–20 °C
Fluid temperature — 5–35 °C
Ambient temperature — 5–45 °C
Rotary-Vane Vacuum Pump
Atmospheric air performance — 755 m3/h
Ultimate partial pressure without gas ballast — 8×10-2 mbar
Ultimate residual partial pressure without gas ballast — 5×10-2 mmHg
Noise level — 75 dB
Motor power — 18.5 kW
Weight — 17 kg
Auxiliary Fore-Vacuum Pump
Pumping speed — 8.5 m3/h
Ultimate partial pressure without gas ballast — 10-4 mbar
Ultimate residual pressure without gas ballast — 2×10-3 mbar
Noise level without gas ballast — 50 dB
Rated power — 0.37 kW
Weight — 18.9 kg
Power Supply
Welding current — AC/DC
Torch cooling — liquid-cooled
Supply voltage — 3×400 V ± 15%
Frequency — 50/60 Hz
TIG current range — 3–500 A
TIG working voltage — 10.1–30.0 V
Ignition voltage — 9.5 kV
Max fluid flow — 1.6 L/min
Coolant volume — 5.5 L
Dimensions (with handle) L×W×H — 625×290×705 mm
Weight — 58.2 kg
Welding Manipulator
Number of axes — 3
Rotation speed range — 0–6 rpm
Load capacity — 500 kg
Workpiece diameter — 0–800 mm
Rotary table angle — ±360°
Tilting range from horizontal axis — ±120°
Table diameter — 900 mm
Vertical travel — 0–350 mm
Number of T-slots — 6
T-slot width — 14 mm
Overall dimensions W×D×H — 1400×1000×1400 mm
Weight — 585 kg
Sample Welding Process in the Chamber
The chamber is made of non-magnetic stainless steel grade 304.
The chamber door is mounted on a sliding trolley.
The chamber features 4 glove ports with a diameter of 150 mm.
Two viewing ports allow the welder to monitor the welding process.
During welding, the levels of H2O, H2O2, and nitrogen in the argon environment inside the chamber are controlled.
Vacuum and overpressure sensors are of a quick-release design.
Gallery of completed projects
