17 May

8 Tips for Using a Plasma Cutting Machines To Improve Results

Plasma cutting machines are so easy to use that it’s tempting to take your new plasma cutting machine out of the box and go to work. However, there are a few practices that can increase your efficiency, improve your cut quality and prolong the life of your equipment.

Whether your plasma cutting machine will be used in the shop or for DIY projects, arts or motorsports, using proper techniques will deliver better results.

Learn more about choosing the right equipment as well as plasma cutting machine setup and operation.

Plasma cutting basics

Plasma provides good quality cutting, gouging and piercing at very high speeds — making this process a good fit for many industries and applications.

The process of plasma arc cutting constricts an open arc by passing it through a small nozzle from the electrode to the workpiece. Although the technology may seem complicated, the process itself is very easy to learn and perform.

The plasma process can be used on any type of electricity-conducting metal and a variety of material sizes — cutting anything from thin-gauge aluminum to stainless and carbon steel up to several inches, depending upon the power of the cutting machine.

The process also provides many benefits compared to oxy-fuel cutting. Plasma cuts faster, a pre-heat cycle is not required, the width of the cut produced is smaller and there is a smaller heat-affected zone, which prevents the surrounding areas from warping.

Keeping a few tips and best practices in mind when choosing and using a plasma cutting machine can help you improve results.

Tip 1: Choose the right plasma cutting machine

Some of the key factors to keep in mind when selecting a plasma cutting machine are output power, cutting speed, input power, duty cycle, and weight and size. Think about the jobs you will do most often when selecting your machine.

Output power: The necessary output power depends primarily on the thickness and type of material to be cut. Power Welds uses two standards: rated and sever cuts. A rated cut is the thickness of mild metal that an operator can manually cut at a rate of 15 inches per minute (IPM). A sever cut is the maximum thickness a plasma cutting machine can handle. The travel speed is slower, and the cut may require clean up.
Cutting speed: This is usually noted as inches per minute (IPM). A machine that cuts 1/2-inch material may take five minutes to do so, whereas another machine may take one. Cutting speed makes a significant difference in production time.
Input power: Will you always be using the plasma cutting machine in the same location, or do you need portability and the ability to use a variety of power sources? Look for plasma cutting machines that offer a range of power options. Some have the ability to switch from 110 volt to 220-volt power.
Duty cycle: Duty cycle is the amount of time a machine can cut within a 10-minute cycle without overheating. If a machine’s duty cycle is 60%, the machine can run continuously for six out of every 10 minutes and then needs to cool for the remaining four minutes. A larger duty cycle is important when making long cuts, in high productivity applications or when using the machine in a hot environment.
Weight and size: If you need portability, many hand-portable units are available that weigh less than 45 pounds. The CUT-40L plasma cutting machines provides the ultimate in portability, weighing only 22 pounds.

Tip 2: Read the plasma cutting machine manual

Thoroughly read the owner’s manual to familiarize yourself with the safe and correct operation of your plasma cutting machine. This will help you optimize your plasma cutting machine’s capabilities and also promote safe use of the machine.

Tip 3: Pay attention to setup

Secure the ground clamp to clean metal only. If necessary, grind off rust or paint, as they inhibit the flow of electricity.

Also, place the ground clamp as close to the cut as possible, or place the clamp on the workpiece itself if possible. Check your cables for worn spots, loose connections or anything that could add unnecessary resistance to electrical flow.

To set the amperage, or heat, of the cutting unit to the proper level, make a few practice cuts with the amperage set high. You can then adjust the amperage down according to your travel speed. If the amperage is too high or your travel speed is too slow, the material you are cutting may become hot and accumulate dross.

Tip 4: Trace the path before cutting

Without pulling the trigger, trace the path you plan to cut. On long cuts, practice your movements before pulling the trigger to make sure you have adequate freedom of movement to make one continuous cut. Stopping and starting again in the same spot is hard and typically creates irregularities in the cut edge.

You can also make a sample cut on the same type of material with which you’ll be working. This helps ensure you’re using the right settings and travel speed.

Tip 5: Use proper technique

Use your non-cutting hand as a support for your other hand. This steadies your cutting hand, provides freedom of movement in all directions and helps maintain a constant 1/16-inch to 1/8-inch standoff. Note that most people find it easier to pull a torch toward their body rather than push it away.

Holding a 1/16-inch to 1/8-inch standoff increases the cutting capacity of smaller machines and extends the consumables life.

Use a drag shield if your machine is equipped with one. This allows you to rest the torch on the workpiece while maintaining an optimal standoff without touching the tip to the metal, which will adversely affect cut quality and consumable life.

Begin cutting by placing the torch as close as possible to the edge of the base metal. Press the trigger to initiate the preflow air; the pilot arc will light, followed by the cutting arc. Once the cutting arc starts, move the torch slowly across the metal. Adjust your speed so that the cutting sparks emerge from the bottom of the metal. At the end of a cut, angle the torch slightly toward the end of the cut or pause briefly to completely finish the cut. The post flow air will continue for a short period after the trigger is released to cool the torch and consumable parts.

Tip 6: Check consumables

If the tip or the electrode become worn or damaged, the quality of the cut will be affected, so inspect your consumables regularly. When the tip hole becomes irregular and/or covered with spatter, discard it. When the tip of the electrode develops a pit, discard it.

The consumables will wear with each cut, but factors like moisture in the air supply, cutting excessively thick materials or poor technique will increase the deterioration of consumables. Best practice is to replace the tip and the electrode together for optimal quality cuts.

Don’t over-tighten the consumables retaining cup. The parts inside actually need to move (become separated) to create an arc, so only finger tighten the cup.

Tip 7: Watch the travel speed

The faster your travel speed (especially on aluminum), the cleaner your cut will be. When cutting thicker material, set the machine to full output and vary your travel speed. On thinner material, turn down the amperage and change to a lower-amperage tip to maintain a narrow kerf.

With a proper travel speed, the arc should exit the material at a 15- to 20-degree angle opposite the direction of travel. If it’s going straight down, it means you’re moving too slowly. If it sprays back, it means you’re moving too fast.

Traveling at the right speed and using the right amount of heat will produce a very clean cut with less dross on the bottom of the cut, as well as little or no distortion to the metal.

Tip 8: Follow plasma cutting safety procedures

Proper plasma safety requires protecting exposed skin. You’ll need welding gloves and a welding jacket or other flame-resistant clothing. Button your shirt cuffs, pockets and collar so they don’t catch sparks.

Shield your eyes with the proper shade lens for the plasma cutting machine you plan to use. The owner’s manual will state the necessary shade for the amperage. You can use traditional plasma cutting/oxy-fuel goggles or a welding helmet with a cutting mode.

Safety procedures must be closely followed in any plasma cutting application.

Optimize plasma cutting

When used properly, your plasma arc cutting unit will provide clean, quality cuts at very high speeds. Following some basic plasma cutting tips and using the right equipment for the job will help you optimize your plasma cutting for better results, increased productivity and lower operating costs.

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17 May

Learn How To Select And Operate a Plasma Cutting Machine For a Variety Of Diy Projects

Plasma cutting is not complicated. As a matter of fact, it’s a relatively straightforward process in which an electric arc is sent through a gas that’s passing through a copper nozzle with a restricted opening. The gas and arc squeeze through the opening and jump from an electrode to the material being cut.Fabricators, contractors, maintenance personnel, artists and do-it-yourselfers who experience the benefits of a hand-held air plasma arc cutting machine rarely want to return to oxy-acetylene cutting or mechanical cutting processes such as saws, cut-off wheels, shears and snips.

Many home repair and renovation projects, as well as hobbies, involve cutting metal materials. These projects may include:

Auto body repair
Metal art sculpting
Repairing small equipment like lawn mowers and snow blowers
Cutting metal studs for garages and home additions
Cutting gutters, down spouts, chain link fencing and clothes line poles
Cutting copper tubing for plumbing projects
Making metal lawn ornaments and holiday decorations
Building and repairing homemade outdoor grills

Often, home hobbyists use metal cutting shears, band saws and oxyfuel cutting torches for metal cutting. However, with new technological advances, air plasma cutting has become an affordable way to cut metal.

Air plasma cutting is a process where an electrical arc passes through a small, constricting nozzle. When a gas, usually air, is introduced, it combines with the electrical current to create a high temperature plasma arc (plasma is a state of matter, unlike solid, liquid or gas). When placed in contact with an electrically conductive material, like copper and stainless steel, the arc passes through the metal, melting a thin area. The force of the arc pushes the molten metal through the workpiece and severs the material. Although the technology behind plasma cutting may seem complicated, the process itself is very easy to learn and perform.

Plasma cutting — a cut above

Plasma cutting provides advantages over other cutting methods. It is quicker and easier than metal cutting shears and band saws. Compared to plasma cutting, shears cannot make radius cuts as tight, and saws are more expensive because they require frequent saw blade replacement, especially when cutting thicker metals.

Compared to oxyfuel torch cutting, the plasma cutting process cuts cleaner and faster and has a narrower cut width. Plasma cutting also has a smaller heat-affected zone, which prevents the surrounding area from warping or damaging paint. In addition, you can use plasma cutting on any type of electricity-conducting metal (the oxyfuel process cannot cut stainless steel or aluminum). Plasma cutting is also a less expensive and more convenient method of metal cutting because clean, dry air is used for most plasma cutting applications.

You can use the plasma cutting process to cut any material that is a good electrical conductor. It works on a variety of material sizes as well – from thin gauge aluminum to stainless and carbon steel up to several inches, depending upon the power of the cutting machine.

Setting-up a plasma cutter

To set-up, simply hook-up the plasma cutting unit to a compressed air source – available in bottles or from a small air compressor. Most plasma cutting units have their own regulator to maintain the proper flow of air for the system.

To set the amperage, or heat, of the cutting unit to the proper level, make a few practice cuts with the amperage set high. You can then adjust the amperage down according to your travel speed. Traveling at the right speed and using the right amount of heat will produce a very clean cut with little or no distortion to the metal.

Operating a plasma arc for cutting

Begin cutting by placing the torch as close as possible to the edge of the base metal. Press the trigger to initiate the preflow air; the pilot arc will then light, followed by the cutting arc. Once the cutting arc starts, move the torch slowly across the metal, maintaining a distance of 1/16″ to 1/8″ from the workpiece. All Power Welds plasma cutters have a drag shield, which lets the operator drag the torch across the workpiece while the torch tip stays the appropriate distance from the metal. Adjust your speed so that the cutting sparks emerge from the bottom of the metal.

You should be able to see the bottom of the workpiece and the arc should be directed straight down. If the sparks are not visible at the bottom of the plate, you have not penetrated the metal. Several factors can cause this: you have not properly grounded the work clamp to the workpiece; your travel speed is too fast; you have insufficient amperage; or you’ve directed the plasma stream at an inappropriate angle.

When nearing the end of a cut, angle the torch slightly toward the outside edge of the workpiece and pause briefly to completely finish the cut. The post flow air will continue for a short period of time after releasing the trigger to cool the torch and consumable parts, however you can resume cutting immediately.

Operating a plasma arc for piercing

Piercing, or creating a hole, can be performed by placing the torch at a 40-degree angle to the workpiece. Press the trigger. Once you initiate the cutting arc, bring the torch tip to a 90-degree angle and the arc will pierce the base metal. Generally, you can pierce up to 1/2 of the maximum cutting thickness provided by the machine.

What to look for in a plasma cutter for DIY use

Output Power. The output power needed depends primarily on the thickness and type of material to be cut. The metal thickness will also determine the size of the nozzle opening, as well as the type and amount of gas or air required.

Determine the type of metal you are planning to cut and then check the cutting capacity of the machine you wish to purchase. Power Welds uses three standards: rated, quality and sever cuts. A rated cut is the thickness of mild metal that an operator can manually cut at a rate of 10 inches per minute (IPM). A quality cut is rated at a slower speed but on thicker metal. A sever cut is the maximum thickness a plasma cutter can handle. The travel speed is slower and the cut may require clean up.

This type of machine works well for most fabrication, maintenance and automotive repair, as well as in hobbyist applications. A more powerful machine may be necessary for operators planning to cut thicker materials.

Cutting Speed and Capacity. Determine the type and thickness of metal you are cutting and your desired cutting speed. Then compare your needs to the cutting capacity and cutting speed of the machine you are considering.

Consumables. Besides compressed air or nitrogen, there can be as few as two consumables needed for plasma cutting. These are the torch tip and electrode. If either the tip or the electrode become worn or damaged, the quality of the cut will be affected. The consumables will wear with each cut, but factors like moisture in the air supply, cutting excessively thick materials or poor operator technique will increase the deterioration of the consumables. You will want to have consumables available when you need them, so the ability to order and receive them in a timely fashion is important. Best practice is to replace the tip and the electrode together for optimal quality cuts. It is especially convenient if the cutting machine has a storage compartment for these consumables.

Weight and Size. Weight and size may be extremely important to consider when purchasing a plasma cutter if you need portability. The CUT-40D AIR PLASMA CUTTER weighs only 10.4kg., allowing the user to carry it comfortably by its shoulder strap.

Related Products

CUT-40D AIR Plasma Cutter

40 AMP PLASMA CUTTER, 16MM MAXIMUM CUT, 60% DUTY CYCLE, PLASMA CUTTING – ANYWHERE, ANYTIME

The CUT-40D Air Plasma Cutter is a powerful machine that cuts through mid-steel, thin copper, thin aluminum, and stainless steel up to 16mm thick with ease, using a 220V power source. Its compact design and lightweight construction make it easy to move around, while the built-in air compressor eliminates the need for an external air supply. With a cutting capacity of up to 16mm at 40A, this plasma cutter is perfect for DIY enthusiasts and professionals alike.

The CUT-40D air plasma cutter is quick switch between built-in and external air pump and designed for maximum performance, capable of clean cutting 8mm and severing 16mm, this machine is for the professional needing maximum power from a portable machine.

Proper safety procedures

As with all industrial products, read the owner’s manual for proper safety procedures.

Closely follow safety procedures followed in any application of the plasma cutting machine. Be aware of potential hazards including high voltages and temperatures, fumes, ultraviolet radiation and molten metal. Proper welding clothing should be worn, as well as welding helmets with dark lenses or appropriate dark safety glasses, as specified by the manufacturer.

Before cutting, inspect the drag shield, tip and electrode and do not operate the unit without the tip or electrode in place. Hitting the torch on a hard surface to remove spatter can damage the torch and stop proper operation. In addition, avoid constant starting and restarting of the plasma arc to lengthen consumable life.

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6 May

The Importance of Having a Built-In Air Compressor for Plasma Cutting Machines

Plasma cutting relies on ionized gas, or plasma, to cut through metal. To create this plasma, a high-pressure air or gas source is necessary. Traditionally, plasma cutters have relied on external air compressors to provide this gas source. However, modern plasma cutters like the 40A Plasma Cutter have a built-in air compressor that provides a reliable and efficient air source for plasma cutting.

So why is a built-in air compressor essential for plasma cutting? Here are a few reasons:

Convenience and Mobility

A built-in air compressor eliminates the need for an external compressor, which means you don’t have to worry about transporting and setting up two separate pieces of equipment. This can be especially convenient if you need to move your plasma cutter from the job site to the job site.

Stable Gas Output

The Plasma Cutter’s built-in air compressor provides a stable gas output, even after long-term use. This is because the compressor is designed specifically for plasma cutting, and can maintain a consistent pressure and flow rate.

Faster Cutting Speeds

Plasma cutting is already faster than traditional cutting methods like Oxyacetylene cutting. However, with a built-in air compressor, the cutting speed can be even faster – up to 2-3 times faster, in fact. This is due to the compressor’s consistent and efficient gas flow.

Less Deformation and Lower Costs

With a stable and consistent gas flow, plasma cutting with a built-in air compressor can result in less deformation of the metal being cut. Additionally, since the compressor is built-in, there are no additional costs associated with purchasing or maintaining an external compressor.

Precise Cutting

Finally, the Plasma Cutter‘s built-in air compressor allows for precise cutting, thanks to its pilot arc starting feature. This feature allows the cutter to start with a small electrical arc, which ionizes the gas and creates the plasma. This precise starting point results in a cleaner and more accurate cut.

Overall, a built-in air compressor is essential for achieving the best results with plasma cutting. With the 40A Plasma Cutter’s built-in reliable high-power air compressor, you can enjoy the benefits of efficient, precise, and cost-effective plasma cutting.

Are you looking for a reliable and efficient plasma cutter that can handle all your cutting needs? Look no further than our highly recommended 40A Plasma Cutter!

The Importance of Having a Built-In Air Compressor for Plasma Cutting Machine — 40A Plasma Cutter – Excellent Cutting Power Thickness16MM

With its built-in reliable high-power air compressor, this machine doesn’t require any additional gas source and provides stable gas output after long-term use. It can cut up to 16mm thickness of stainless steel with ease, and it’s 2-3 times faster than the Oxyacetylene cutting speed, saving you time and money.

The quick switch between the built-in and external air pump and the pilot arc starting function increases cutting capability and speed, while the overheat, overcurrent, and overvoltage protection ensure safe and secure operation. The simple operation and smooth precise cutting make it an ideal choice for both professional and DIY users.

So if you want a plasma cutter that can handle all your cutting needs, go for our highly recommended 40A Plasma Cutter. Trust us, you won’t be disappointed!”

powerwelds Welding Tips

26 March

How to Select Air Compressor for Your Plasma Cutter

Plasma is a superheated ionized gas. In a plasma cutter air compressor system, you can think of this as a lightning bolt inside a tornado. For a small handheld plasma cutter running at 20-30 amps, you’ll need as little as 80 psi (5.5 bar). Larger, automated plasma cutting systems in the 130 to 800 amp range may require 115 psi (8 bar) or more.

The electrical current (lightning bolt) contains a massive amount of heat energy. The gas (tornado) ionizes, controls the arc, and blows away the molten material. In order for a plasma cutting system to perform optimally, the gas supply must be clean, dry, and properly regulated. When using bottled gas, these factors are relatively simple to control. Since most modern plasma cutting systems rely on shop air for the majority of cutting processes, it introduces more variables into the equation. Oftentimes, this causes performance and consumable life to suffer when the air supply is less than ideal.

Here, we’ll discuss the three factors that contribute the most to the performance of your plasma-cutting system and how to make sure that your tornado can keep up with your lightning bolt.

Before we can discuss what a plasma cutter needs to breathe, we need to understand the design and operation of air compressors.

About Plasma Cutter Air Compressors

A typical air compressor comprises of a motor-driven compressor and a storage tank. The storage tank size is represented in gallons or liters. Portable systems have tanks as small as 1 gallon, and stationary systems have tanks of 100 gallons or larger.

Flow rate capacity is a product of output pressure and storage tank size. The higher the output pressure is set, the lower the flow rate capacity will be. It is important that you are confident your compressor can keep up with the flow rate requirement of your cutting system when set at the required output pressure.

It is highly recommended that your plasma cutter air compressor be dedicated to running your plasma cutting system. If you plan to run other pneumatic devices simultaneously, you will have to add the flow rate requirements of all devices together. This ensures that your compressor can keep up without exceeding its duty cycle.

1. Pressure

Pressure is the force of the compressed air being fed to your plasma cutter. The value for gas pressure may be represented in pounds per square inch (psi), megapascal (MPa) or bar.

Air compressor system pressure is preset and usually between 100 psi and 135 psi. Output pressure is adjustable via the pressure regulator. Inlet pressures vary by system. For a small handheld plasma cutter running at 20-30 amps, you’ll need as little as 80 psi (5.5 bar). Larger, automated plasma cutting systems in the 130 to 800 amp range may require 115 psi (8 bar) or more.

Most commercial industrial air compressors for plasma cutters will be capable of generating pressures in this range. It is important to note that the inlet pressure at your plasma cutting system will be lower than the output pressure of your air compressor due to pressure drops between the two points which can be caused by leaks or restrictions such as undersized fittings or filtration units.

You may need to set your compressor’s output pressure slightly higher than the inlet pressure requirement of your plasma cutter to compensate for pressure drops. Consult your operator’s manual to determine the best pressure for your system.

2. Flow

Flow is the rate at which air is being fed to your plasma cutter from the air compressor.

The value for flow rate may be represented in cubic feet per minute (CFM or ft3/min), standardized cubic feet per minute (SCFM), cubic feet per hour (CFH or ft3/h), standardized cubic feet per hour (SCFH), liters per minute (l/min), or liters per hour (l/hr). The size of the tank largely determines the flow capacity of the compressed air system.

As a good rule of thumb, select a compressor that has a flow rate capacity of at least 1.5 times the consumption rate of the plasma cutter. You’ll also want to make sure that the hose or tubing in use is rated for the pressure the system will handle, large enough in diameter to handle the flow rate requirements, and will not corrode or cause excess moisture to develop inside the line.

Copper is preferable to steel and aluminum pipe. Lines shorter than 75’ should use 3/8” diameter hose or tubing. Lines longer than 75’ should use ½” diameter hose or tubing. If using a flexible hose, you should make sure not to pinch or kink the hose.

The orifice size of all fittings used should match the ID of the hose or tubing. Flow rate requirements also vary by system. You’ll need between 3.5 scfm (99 l/min) and 6.7 scfm (189 l/min) depending on your system’s requirements.

3. Filtration

While inlet pressure and flow rate vary by system, filtration requirements do not. At the surface level, it may seem that this makes filtration the simplest variable to account for.

In truth, filtration is the biggest gremlin in many air supply systems because it is often misunderstood. Operators assume that because they have invested in the proper filtration equipment, they cannot possibly be experiencing a filtration issue.

The design and layout of a compressed air system can have a large impact on the amount of moisture that becomes trapped in the system, and where it ends up. Gravity can be your friend or enemy in this regard. You should use air filtration devices to remove water, oil, and debris from your air supply. Place these as close to the plasma cutting system as possible.

Under most conditions, a common coalescing filter with an automatic drain is sufficient. If cutting in a high-humidity environment, consider a refrigerated air dryer.

Taking the time to ensure a proper supply of clean dry air to your plasma cutting system will provide you with better cut quality, less downtime, and longer-lasting consumables. If you need help selecting the proper air compressor or air system components, visit your local supplier for assistance!

PLASMA GAS SELECTION GUIDE

Plasma Gas	Shield Gas	Mild Steel	Stainless Steel	Aluminum
Air	Air	Good cut quality Economical	Good cut quality and speed Economical	Good cut quality and speed Economical
Oxygen	Air	Excellent cut quality and speed Very little dross	Not recommended	Not recommended
Nitrogen	Carbon Dioxide	Fair cut quality Some dross Excellent parts life	Good cut quality Excellent parts life	Excellent cut quality Excellent parts life
Nitrogen	Air	Fair cut quality Some dross Excellent parts life	Good cut quality Excellent parts life	Good cut quality Excellent parts life
Nitrogen	Water	Fair cut quality Some dross Excellent parts life	Excellent cut quality Excellent parts life	Excellent cut quality Excellent parts life
Argon Hydrogen	Nitrogen	Not recommended	Excellent on thicknesses above 1/2″	Excellent on thicknesses above 1/2″

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