Anyone experienced with plasma welding (PAW)?

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Our product requires welding the ends of tens of thousands of small stainless wires in T304, .035" dia.  Welds are about 1/10" apart and it is not the kind of set up that can be mechanized (variations upon variations).  No filler is added.  Photo's were so small that they came out poorly so you'll have to use your imagination.  Basically think of it like putting balls on the ends of tiny wires where they cross to form a joint.It's currently done via tig by guys who must be a bit crazy in the first place to not be driven over the edge by the repetition.I always wanted to try PAW for this welding and recently have seen a number of the old Linde small PAW systems at auction.  Having never actually used one, I was curious for some feedback from someone who might have.  Finicky systems?  Point me to a modern version of a low amp PAW that you might recommend?  Gobble up consumables like candy?  I'm totally ignorant on the subject to any feedback would be helpful.  Are those old Lindes that show up a decent machine to convince proof of concept with or just boat anchors (assuming they're in workable shape, of course)?This is something I've been trying to get tested for years but got too much push-back from the old-school powers.  The best I got was as far as a welding supply place loaning us a test machine...which was never tested (factory is different location than I am).  Those dinosaur guys are no longer a factor so I might have a chance to move forward again.  It'd be nice to have some feedback from actual experience, thoughMy experience in PAW is limited to reading...so anything you can add is better than what I'm working with now.
Reply:The little bit of experience I had with it was it is a pretty good set up. We used a Thermal Arc machine, I wasn't privy to the set up information as too many hands were getting in and changing them. I do remember that the welds were dead nuts on and the repeatability was great. The tungsten had to be kept at a very precise gap from the part being welded and once it lost its point the welds went to hell real fast. The argon had to be pretty precise also. All in all I thought it was a pretty interesting way of welding. It seemed to be pretty good at welding parts that weren't the absolutely cleanest . This was done on an automated process.  We were welding a heavier material than what you're describing.One more thing I just thought of, parts must be consistent and not vary. Our set up was not forgiving on poor part fitment or out of tolerance parts.Last edited by bfjou812; 10-17-2014 at 12:37 AM.