HOW THE PLASMA CUTTING PROCESS WORKS

Plasma – The Fourth State of Matter.

Matter exists in four states. They are solid, liquid, gas and plasma. Adding ever increasing energy causes a solid to become a liquid,
then a gas. And finally, a plasma is created when enough energy is applied. The resulting plasma is now capable of carrying
electrical current like a copper wire. Lightning is naturally occurring plasma.

SKIP TO A SECTION

 Plasma Cutting Process

 Pilot & Transferred Arc
 Double arc
 Basic Torch Design
 Direction of Cut Path
 Single & Dual Gas Torches
 Plasma Terminology

PLASMA CUTTING PROCESS

Plasma arc cutting is capable of cutting all metals. The process is commonly used to cut steel, stainless steel and aluminum. Plasma
cutting systems range in amperage output from 20 to 1,000 amps. High definition plasma systems using oxygen as the plasma gas
have a capacity of piercing and production cutting steel up to 2.0” at 400 amps. High power systems using plasma gas mixtures of
argon and hydrogen have the capacity to cut up to 6.0” stainless or aluminum at 1,000 amps.

Plasma Arc Cutting (PAC) power supplies are the Constant Current (CC) type as are powers supplies used for stick electrode (SMAW)
and TIG welding (GTAW). However, PAC power supplies output much higher voltage. Open circuit voltage may be as high as 400
VDC. Constricting the plasma jet through a nozzle increases the arc density. Plasma cutting torches include a component to swirl
the plasma gas forcing non-ionized gases outward. Swirling the plasma gas causes the cooler un-ionized boundary layer of gas
around the plasma column to become wider, squeezing the arc and further increasing the arc density, length and temperature.
Swirling the plasma gas also increases nozzle life.  The plasma arc column can achieve temperatures of approx. 24,000º K (or
42,000º F).
PILOT ARC (NON-TRANSFERRED)

A low current non-transferred pilot arc is established within the torch between the negatively charged electrode and the positively
charged nozzle to provide a path for the cutting arc to transfer to the positively charged work piece. Plasma cutting systems with
output over 125 amps ionize the plasma gas by applying a momentary burst of high frequency between the electrode and nozzle.
The thousands of volts of high frequency provides a path for the DC component of the pilot arc. The instant DC current is measured
between the electrode and nozzle, the high frequency component of the pilot arc is turned off. The plasma gas flow causes the DC
arc to be blown out of the orifice and reattach to the face of the nozzle.

TRANSFERRED ARC

If the torch is close enough to the work-piece while the pilot arc is on, the main cutting current will seek to attach to the work piece.
When current flow is measured between the electrode and the work piece, the DC component of the pilot arc is turned off. The high
temperature, high velocity plasma stream melts and blows the molten material through the work-piece.

The plasma power supply supplies a contact closure to the cutting machine when the main cutting arc has transferred. This signal is
often called the “OK to Move” signal. Cutting machine motion is delayed until the arc has fully penetrated to material. This delay is
called “Pierce time”.

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DOUBLE ARC

The cutting arc normally passes through the nozzle orifice without contacting the nozzle. A condition called a “double arc” occurs
when the cutting arc attaches to the work piece via the nozzle. A double arc normally severely damages the nozzle. A single double
arc can render the nozzle incapable of producing a quality cut.

A Double Arc May Occur When:

 The nozzle is too close to the material during the pierce

 Excessive metal builds up on the face of the torch shield
 Machine motion is initiated prior to the arc penetrating the metal causing molten metal to attach to the front of the torch
 Plasma gas flow is too low
 Cutting amperage is set too high

Double Arc
BASIC TORCH DESIGN

Plasma torches are either a single gas or dual gas design. Typically, single gas design torches operate at up to 125 amps and are
cooled by the gas flowing through them. The single gas input is split inside the torch into the plasma and shield flows. Over 125
amps, the increased heat of the arc requires that the torch is liquid cooled. Virtually all liquid cooled torches are the dual gas type.
Dual gas torches have separate pathways for the plasma and shield gases allowing the torch leads to deliver the gases to the torch
head through two separate hoses. The plasma and shield gases can therefore be different and delivery pressures and flows can be
different as well.

Basic Plasma Torch Design

DIRECTION OF CUT PATH

Because the plasma gas is rotating, the cut is squarer on one side. With a clock-wise swirl direction, the cut on the side in the
direction of travel is the squarer side. CNC controls designed for plasma cutting automatically produce motion that accounts for this
directionality.

SYSTEMS WITH SINGLE GAS TORCHES

Low cost automated plasma cutting systems are configured with single gas torches designed to cut all metal types using shop
compressed air. Prices for automated air plasma cutting systems range between $3,500 (40 amp) and $10,000 (125 amp). Please
note that these prices are for a plasma cutting power and torch – not a complete CNC cutting machine. This type of plasma system
has become extremely popular with metal fabricators doing ornamental metal work and relatively low production general purpose
plate cutting.
SYSTEMS WITH DUAL GAS TORCHES

Today’s automated precision plasma cutting systems are priced at approximately $40,000 (130 amp systems), $75,000 (400 amp
systems) and $125,000 (800 amp systems). Please note that these prices are for the plasma cutting power and torch – not a
complete CNC cutting machine. They are configured with liquid cooled dual gas torches, computer-controlled switch-mode power
supplies and sophisticated automatic gas delivery systems. Cut charts embedded into today’s CNC controls automatically adjust
cutting parameters and select the required gases based on the material and thickness selected. Also, most precision plasma systems
include technology which ramps amperage and gas flow at the start and stop of every cut. This technology significantly extends
consumable life and delivers extremely consistent cutting performance over the life of consumables

PLASMA CUTTING TERMINOLOGY

Plasma cutting does not produce cut edges that are exactly 90° to material surface. The bevel angle is amount the cut is off from
Bevel Angle
square.

Non-conductive material molded within the torch body that electrically insulates between the negative and positive portions of
Center Insulator
the torch.

A relatively low-cost plasma cutting system comprised of a DC power supply, torch and a low-cost gas delivery system such as
pressure regulators attached to the source of gases. Such systems produce arcs with a density of approximately 30,000 amps per
Conventional
square inch. Cut bevel angles of 5° to 7° are common. These systems may be offered for both hand and mechanized applications.
Plasma
When used on a CNC cutting machine in a steel application, the smallest recommendation hole is generally 2 times the material
thickness, i.e. 1/2″ in 1/4″ material.

Cutting Arc A transferred arc that passes through the nozzle and is established between the electrode insert and the material being cut.

Material that remains on the bottom of a plate after cutting. Dross can also be on the top of the plate, usually when cutting height
Dross
is excessive.

Torches designed to operate with separate inputs for the plasma and shield. Dual gas torches may be either air cooled or liquid
Dual Gas Torch cooled. The plasma and shield gases may be the same or different. By optimizing the plasma gas and shield gas based on
material and thickness, dual gas torches produce the highest cut quality.

Electrode Copper element with an insert of tungsten or hafnium. The electrode is connected to the negative output of the DC power supply.

A significantly higher priced plasma cutting system comprised of a sophisticated switch-mode DC power supply, precision torch
and a computer-controlled highly accurate gas delivery system mounted very near the torch. Such systems produce arcs with
High Definition
extremely high arc densities of 60,000 amps per square inch or more. Cut bevel angles of 1° to 3° are common. These systems
Plasma
are offered only for mechanized operation. When used on a CNC cutting machines in a steel application, the smallest
recommended hole is 1 times the material thicknes, i.e. 1/4″ in 1/4″ material.

The amount of material removed by cutting arc. CNC controls offset the cut path by 1/2 the kerf to insure the final part is the
Kerf correct size. Kerf widths range from .019″ at 45 amps using N2/N2 cutting stainless steel to .340″ at 400 amps using O2/Air
cutting mild steel.

Nozzle (tip, Copper element to focus the plasma stream. The nozzle is connected to the positive output of the DC power supply via a
orifice) normally open relay contact. The pilot arc relay is momentarily closed to create the non-transferred pilot arc.

A non-transferred arc established between the electrode and nozzle in a plasma torch. The pilot arc excites the orifice gas
(plasma) into becoming plasma. In liquid cooled torches, the arc is commonly comprised of a momentary burst of high
Pilot Arc
frequency and followed by DC current. Many low amp air cooled air plasma torches use a moving element within the torch to
“strike” an arc between the electrode and nozzle which eliminates the need for high frequency.

Plasma Gas Orifice gas used to conduct current to and through the metal being cut.

Directs shield gas (secondary) flow around the nozzle (tip) and at the cut. In some torch designs, it also holds the parts in the
Shield Cap (Cup)
torch.

Shield Gas Cooling and cut assist gas. Torch design focuses flow around the nozzle to reduce the possibility of a “double arc”, squeeze the
(Secondary) cutting arc and to wash slag off the bottom of the cut.

Torches designed to operate with a single supply of gas input, generally shop compressed air. Single gas torches split the input
Single Gas Torch
flow into plasma and shield flows within the torch. These torches are normally air cooled.

Swirl Ring (Gas Non-conductive material which includes extremely small holes that cause the plasma gas to swirl. Some torches use the swirl
Distributor) ring to set the gap between the electrode and nozzle.

PLASMA CUTTING SOLUTIONS

Previous
ROBOVENT FUSION
Fume Extraction Collector Series

As the recommended fume extractor for our plasma cutting machines, the Fusion Collectors from RoboVent offer perfect air quality
solution for cutting-edge processes.

HYPERTHERM HPR400XD
HyPerformance Plasma

The HPR400XD with PowerPierce and True Hole technology are available to be configured with our plasma cutting machines.

ZONED DOWN AIR DRAFT

Cutting Table

The Zoned Down Air Draft table with mechanically activated zone damper doors offers the cut quality benefits of cutting dry and
excellent fume extraction.

WATER TABLE
Cutting Table
The Water Table with adjustable water level offers a lower cost, good fume capture and reduced plate warpage.

KANO™ HD
CNC Plasma Cutting

KANO™ HD is a true unitized CNC cutting machine available in six machine sizes configured with a Hypertherm plasma system and
your choice of three cutting table styles.

HYPERTHERM XPR SERIES

X-Definition™ Plasma

The XPR170 and XPR300 with PowerPierce and True Hole technology are available to be configured with our plasma cutting
machines.

TRACKLEAN™
Self-Cleaning Table with AirSweep

The TracKlean table is comprised of two unique traveling cars, each with a slag bin and a detachable plow for fast part retrieval and
easy cleaning.
ROBOVENT FUSION
Fume Extraction Collector Series

As the recommended fume extractor for our plasma cutting machines, the Fusion Collectors from RoboVent offer perfect air quality
solution for cutting-edge processes.

HYPERTHERM HPR400XD
HyPerformance Plasma

The HPR400XD with PowerPierce and True Hole technology are available to be configured with our plasma cutting machines.

ZONED DOWN AIR DRAFT

Cutting Table

The Zoned Down Air Draft table with mechanically activated zone damper doors offers the cut quality benefits of cutting dry and
excellent fume extraction.

WATER TABLE
Cutting Table
The Water Table with adjustable water level offers a lower cost, good fume capture and reduced plate warpage.

KANO™ HD
CNC Plasma Cutting

KANO™ HD is a true unitized CNC cutting machine available in six machine sizes configured with a Hypertherm plasma system and
your choice of three cutting table styles.

HYPERTHERM XPR SERIES

X-Definition™ Plasma

The XPR170 and XPR300 with PowerPierce and True Hole technology are available to be configured with our plasma cutting
machines.

TRACKLEAN™
Self-Cleaning Table with AirSweep

The TracKlean table is comprised of two unique traveling cars, each with a slag bin and a detachable plow for fast part retrieval and
easy cleaning.
ROBOVENT FUSION
Fume Extraction Collector Series

As the recommended fume extractor for our plasma cutting machines, the Fusion Collectors from RoboVent offer perfect air quality
solution for cutting-edge processes.

HYPERTHERM HPR400XD
HyPerformance Plasma

The HPR400XD with PowerPierce and True Hole technology are available to be configured with our plasma cutting machines.

ZONED DOWN AIR DRAFT

Cutting Table

The Zoned Down Air Draft table with mechanically activated zone damper doors offers the cut quality benefits of cutting dry and
excellent fume extraction.

WATER TABLE
Cutting Table
The Water Table with adjustable water level offers a lower cost, good fume capture and reduced plate warpage.

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Of all the companies we deal with in the equipment and tooling portion of our business, Park Industries response and service are
the very best.

Grant Layman
Spraggins Fabrication and Supply

After researching many plasma tables on the market, we were excited about our decision to go with Park Industries®. The
capabilities of the KANO™ have given us the confidence to take on a more diverse range of jobs than we would have before. The
 easy communication we have with tech support when any issues arise makes operating our Kano stress-free so we can focus on
building our business. We are constantly finding new ways to incorporate the machine into our daily operations.

Mike Brenseke
Brenseke Welding & Fabricating

Park’s customer service has been beyond helpful and we couldn’t be happier with the KANO HD CNC Plasma Cutting Machine.

Max Steck
Brenseke Welding & Fabricating
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