Feb. 28, 2022
Plasma cutting is a process that we have seen evolve from its humble beginnings in the 1960s to its current popularity as a widespread cutting technology for a wide range of industries, from manufacturing shops to automotive repair and restoration to industrial construction to salvage and scrap operations.
In this blog, we will take an in-depth look at what plasma cutting is and how it works, as well as the advantages and disadvantages of the technology.
Plasma is a conductive, ionized gas-like substance. It has long been used as a very effective material for cutting steel, stainless steel, aluminum, brass, copper and many other conductive metals in the correct environment.
Following the application of computer numerical control (CNC) technology in the 1980s and recent manufacturing improvements, plasma cutting machines not only offer advantages over conventional cutting due to the absence of metal chips, producing cleaner edges, but also now offer more flexibility to cut a variety of shapes in a variety of materials with laser-like precision.
The basic process of plasma cutting is to create an electrical path of superheated ionized gas (i.e., plasma) from the plasma cutter to the workpiece to be cut. A combination of high voltage electrodes and protective gas in the cutter moves the induced plasma downward at high speed through a focusing nozzle. The ionized, superheated and concentrated plasma beam then melts and jets any metal it comes in contact with, producing a clean cut every time.
► Plasma cutting machines offer a low cost and high speed technology, so it is not surprising that it has become a favored method for many industries. Most similar techniques take about a quarter of the time to completely break a workable piece of metal.
► Plasma cutting machines have the added advantage of being highly portable. The cutter itself can be miniaturized to the size of a handheld device and therefore can be easily transported.
► Plasma equipment is considered both value for money and energy efficient, with a 1:2 ratio per cut compared to oxygen cutting.
► Plasma cutting relies on inert gas and is therefore safer than oxygen cutting, which has the potential to explode.
►Plasma torches can be used to create very precise cuts, allowing users from large industrial applications to small hobby stores to easily produce cuts ranging from odd shapes to curved cuts.
►Most plasma cutters are not as useful for thicker or denser materials. For materials with greater depth, you will have to use more traditional methods.
►Although heat exposure is reduced, plasma cutting is inevitably noisy and can produce excessive fumes, so make sure your shop is adequately ventilated.
►Plasma cutting does have a smaller cut kerf than methods such as flame cutting. However, laser cutting has a smaller kerf and a smaller heat affected zone (HAZ), resulting in a higher quality finish, especially on thinner materials.
► Plasma torches are known for producing bright flashes of light, and there is a risk of sparks flying when cutting. Therefore, a high degree of care must be taken by all employees who are near or using the plasma cutter. Make sure the work area is clean and free of flammable liquids and gases, and that you have the proper personal protective equipment, from face shields to goggles to leather gloves, aprons and jackets.
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