Metal inert gas welding system for use in vacuum

An inert gas welding device, comprising:

• a substantially spherical pre-plasma cavity having (a) a first opening therein capable of accepting an inert gas into said pre-plasma cavity, (b) first and second electrodes within said pre-plasma cavity capable of applying a radio frequency electromagnetic field to said inert gas to thereby convert said inert gas into a plasma and (c) a second opening capable of allowing said plasma to exit said pre-plasma cavity;
• means for directing said plasma from said second opening of said pre-plasma cavity to a substantially hemispherical arc welding cavity adjacent said second opening, said means for directing comprising an electrical potential difference between said inert gas welding device and said working surface and a repeller plate surrounding said arc welding cavity, said arc welding cavity capable of being placed adjacent to a metal working surface, said arc welding cavity further capable of accepting a metal welding material therein, said plasma impinging on said metal working surface and said metal welding material to thereby heat said metal working surface and said metal welding material, said directing means focusing said plasma within said arc welding cavity to thereby increase a rate of heat transfer between said plasma and said working surface and said welding material;
• means for regulating a flow rate of said inert gas into said pre-plasma chamber;
• means for regulating a rate of introduction of said welding material into said arc welding cavity;
• and
• means, coupled to said inert gas welding device, for cooling said inert gas welding device.

A method of welding, comprising the steps of:

• accepting an inert gas into a first opening of a pre-plasma cavity within an inert gas welding device;
• applying an electromagnetic field to said inert gas with first and second electrodes within said pre-plasma cavity to thereby convert said inert gas into a plasma, said pre-plasma cavity confining said plasma and inhibiting a plasma flow from said cavity into a low pressure or vacuum environment surrounding said welding device;
• allowing said plasma to exit a second opening of said pre-plasma cavity;
• directing said plasma from said second opening of said pre-plasma cavity to an arc welding cavity within said inert gas welding device and adjacent said second opening;
• placing said arc welding cavity adjacent to a working surface;
• accepting a welding material into said arc welding cavity;
• impinging said plasma on said working surface and said welding material to thereby heat said working surface and said welding material;
• and
• focussing said plasma within said arc welding cavity to thereby increase a rate of heat transfer between said plasma and said working surface and said welding material.