Plasma Cutting Machine: Function, Advantages, and Disadvantages

There are multiple metal cutters in the market. To cut thick metal sheets, plasma cutters are widely used.

Plasma cutting is a thermal cutting method where ionized gas is used to cut the metals. Plasma is the fourth state of matter found in the upper parts of the earth’s atmosphere. The polar lights are made of solar winds made of plasma. In daily life, we see a lot of electronic appliances like plasma TV, neon signs, fluorescent lamps, etc. To learn more about plasma cutters and to understand how they work, keep reading.

How Plasma Cutters Work?

Plasma cutters use thermal energy i.e. heat to cut the metals. They have compressed gas like nitrogen that is ionized. This ionization of gases creates palma. The compressed gas comes in contact with the electrode and the pressure is created to ionize the gas. Slowly the pressure builds up and the stream of plasma is pushed towards the cutting head. This head constricts the stream and then subjects it towards the workpiece. 

The plasma is conductive and so the workpiece is connected at the ground of the cutting cables. The plasma arc comes in contact with the metal and due to high temperature the metal melts. And at the same time the molten metal is blown away by the air flow.

Consumables

As plasma cutters use heat to cut materials, there are parts in the cutter that require regular replacement. The hand held plasma cutter parts like nozzle, lenses, hypertherm powermax 85 consumables, etc. must be replaced regularly because they can affect the cutting quality if not in proper condition. Also, the quality of the consumables suggest how long they will last. The consumables must be replaced by the trained or certified technician because if they are not fixed properly, they can affect the quality of the cut, destroy the cutting sheet and also the machine in the worst case scenario. You must consider the maintenance charges and cost of replacement parts while setting a budget for the machine. 

Advantages of Plasma Cutting Machine

Here are some reasons you must invest in a plasma cutting machine.

• Plasma cutters can cut almost all conductive materials

• No need to warm up the laser cutter

• They are suitable to cut thick metal sheets up to 50 mm to receive the best cut quality and maximum up to 150 mm

• They are affordable

• They are the best for stainless steel and aluminum

• They have high precision

• Also suitable for inwater cuts which can reduce noise levels as well

• They are fast when compared to oxy fuel

• Can be used for welding

• Less risky

Disadvantages of Plasma Cutting Machine

No machine is perfect. Here are some disadvantages of the cutters which you must know before buying one.

• The heat affected zone (HAZ) is larger compared to other laser machines

• Requirement of hypertherm powermax 85 consumables is high and it can cost you more

• They have better quality with thinner sheets and plates

• They have less tolerances

Conclusion

The plasma cutter machine is best if your business requirement needs you to deal with multiple types of materials. The shelf life of the machine is long if they are maintained properly. The hand held plasma cutter parts require regular maintenance. You must clean them daily to ensure you have beautiful precise cuts every time you use it. The next thing is trying the first cut on a sample piece to avoid ruining the actual sheet. Once all the settings are proper, you can continue with larger orders.

 

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/plasma-cutting-machine-function-advantages-and-disadvantages

What is Plasma Cutting and What are Plasma Cutter Consumables?

Plasma cutters have the capability to cut the metals in simple and complex shapes like holes, edges, markings, etc. Plasma cutters are cost-effective and practical compared to oxy-fuel, laser, and water jet cutting processes. Let us understand how plasma cutters work and what consumables you will need.

What is Plasma Cutter?

Plasma cutting is a cutting technique that uses an accelerated jet of hot plasma to cut through conductive metals like steel, aluminum, brass, titanium, copper, etc. It is widely used in manufacturing, automotive repair, industrial construction, restoring, scrapping, etc. Plasma cutting can be done using a handheld plasma torch also known as plasma arcs, guns, or cutters. For that, you will need hand held plasma cutter parts.

Due to high speed, precise cuts, and low cost, plasma cutting is widely used by small companies and industries using CNC. 

Why You Need Plasma Cutter Consumables?

Using plasma cutter over time, components start wearing off gradually. Worn consumables can ruin metal while cutting. Your operator can tell which consumables are worn by sound, color, etc. 

The best way to keep a check on the condition of your consumables is to periodically inspect consumables. If you see that the quality of the cut is deteriorating, you have an indication that it needs to be changed. 

It is a good practice to maintain a record of the average life of parts over time and prepare a guideline for consumables based on the thickness of the material, amperage, and material. So operator will know after what time he needs to check the components thoroughly to prevent catastrophic failure.

It is essential that you run all your parts at the correct amperage. High or low amperage can impact the cut quality. However, using incorrect consumables can also lead to shortened life and cut quality. 

List of Consumables With Their Purpose

You can choose from different consumables like Hypertherm powermax 45 consumables, Powermax 45 XP, Powermax 65, etc. Here is the list of the consumables you might need.

Electrode

The electrode provides power to the plasma arc. Electrode conducts high voltage or high-frequency energy while you start the cut. This adds energy to ionize the cuttings gas that creates plasma and allows the arc to start.

Swirl Ring

A swirl ring is made of ceramic or volcanic ash. It controls and swirls the plasma gas around the electrodes and inside nozzles. It basically controls the point where the arc is attached to the emitter and also the plasma flow through the nozzle that affects the edge angularity. It usually swirls in clockwise rotation but their counterclockwise swirls are to assist for mirror cutting.

Nozzle

Nozzle constricts the gas stream flowing through the orifice in the center of the nozzle. A nozzle that is worn out or improper will cause the part to have an improper size or edge. The orifice must be a circle and not oval or egg-shaped. 

Inner Retaining Cap

The purpose of the retaining cap is to hold all the internal stack components in proper alignment. A damaged or improper retainer will cause the rest of the consumables to fit improperly and it can cause a gas error, coolant leaks, or poor cut quality.

Shield Cap

As the name suggests, a shield protects all the consumables from sparks and molten metals. There are mostly made of copper and provide a proper distance between nozzle and workpiece.

Water Tube

It works as a coolant to the tips of the electrodes to prevent overheating. The size of the tube is important otherwise it will cause premature electrode failure due to overheating.

Conclusion

It is important to invest in a good-quality hand held plasma cutter parts. Because poor quality will have less shelf-life. You can find different Hypertherm consumables like Hypertherm powermax 45 consumables, powermax 45XP, powermax 65, etc. easily from certified suppliers.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/what-is-plasma-cutting-and-what-are-plasma-cutter-consumables