Technology

Vocational Livelihood 11
Shielded Metal Arc Welding

Quarter 1
Self-Learning Module 5
TITLE : PLASMA CUTTING MACHINE
Writer : Rubener P. Tacsay
Reviewer : Orlando A. Joven Jr (Validator)
Emmanuel B. Penetrante (Technical)
 EXPECTATIONS

At the end of this module, the learners will be able to:

 define the meaning of Plasma cutting machine;
 identify the different part of Plasma; and
 explain how plasma uses as cutting machine

PRETEST

Directions: Write the letter of the correct answer in every items. Provide separate
answer sheet.

a. welding
b. Oxy-fuel
c. Plasma
d. Torches
2. This is a process that cuts through electrically conductive materials by means of
an accelerated jet of hot plasma
a. welding
b. Oxy-fuel cutting
c. Plasma cutting
d. Torches
3. Plasma cutters produce a very hot and very localized fire called?
a. Cone
b. Flame
c. Weldment
d. stinger
4. This is an arc forms within the torch head, with current flowing from the electrode
to the nozzle inside the torch head
a. Cone
b. Fume
c. Weld
d. Pilot
5. This is the recommended Number of green lens shade to use during plasma
cutting
a. #4
b. #5
c. #6
d. #8
 RECAP

What are the different parts of oxy-acetylene cutting torches?

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LESSON

QUARTER 1: Time Allotment: 40 Hours

PLASMA CUTTING EQUIPMENT

PLASMA is a Gas that has been heated to a high temperature and converted
(ionized) so that the gas become electrically conductive. The plasma cutting process
uses plasma to transfer an electric arc to the metal. The metal is heated to its
melting point by the heat of the arc and is blown away by air

Plasma cutting is a process that cuts through electrically conductive materials by

means of an accelerated jet of hot plasma. Typical materials cut with a plasma
torch include steel, stainless steel, aluminum, brass and copper, although other
conductive metals may be cut as well. Plasma cutting is often used
in fabrication shops, automotive repair and restoration, industrial construction,
and salvage and scrapping operations. Due to the high speed and precision cuts
combined with low cost, plasma cutting sees widespread use from large-scale
industrial CNC applications down to small hobbyist shops.

Source: https://en.wikipedia.org/wiki/Plasma_cutting/ Plasma cutting with a tilting head

The basic plasma cutting process involves creating an electrical channel of
superheated, electrically ionized gas i.e. plasma from the plasma cutter itself,
through the work piece to be cut, thus forming a completed electric circuit back to
the plasma cutter through a grounding clamp. This is accomplished by a compressed
gas (oxygen, air, inert and others depending on material being cut) which is blown
through a focused nozzle at high speed toward the work piece. An electrical arc is
then formed within the gas, between an electrode near or integrated into the gas
nozzle and the work piece itself. The electrical arc ionizes some of the gas, thereby
creating an electrically conductive channel of plasma. As electricity from the cutter
torch travels down this plasma it delivers sufficient heat to melt through the work
piece. At the same time, much of the high velocity plasma and compressed gas blow
the hot molten metal away, thereby separating, i.e. cutting through, the work piece.

Source: https://en.wikipedia.org/wiki/Plasma_cutting/ Freehand cut of a thick steel plate

Plasma cutting is an effective way of cutting thin and thick materials alike. Hand-
held torches can usually cut up to 38 mm (1.5 in) thick steel plate, and stronger
computer-controlled torches can cut steel up to 150 mm (6 in) thick.[1] Since plasma
cutters produce a very hot and very localized "cone" to cut with, they are extremely
useful for cutting sheet metal in curved or angled shapes.

Source: https://en.wikipedia.org/wiki/ Plasma cutting with a tilting head

The arcs are generated in a three-step process. A high voltage spark briefly ionizes
the air within the torch head. This makes the air conductive and allows the "pilot
arc" to form. The pilot arc forms within the torch head, with current flowing from the
electrode to the nozzle inside the torch head. The pilot arc burns up the nozzle, a
consumable part, while in this phase. The air then blows the plasma out the nozzle
towards the work, providing a current path from the electrode to the work. When the
control system senses current flowing from the electrode to the work, it cuts the
electrical connection to the nozzle. Current then flows from the electrode to the work,
and the arc forms outside the nozzle. Cutting can then proceed, without burning up
the nozzle. Nozzle life is limited by the number of arcs starts, not cutting time.
PARTS OF PLASMA CUTTING MACHINE

Source: https://en.wikipedia.org/wiki plassma-cutting-systems-parts-model-system-653-phase

Setting-Up A Plasma Arc Cutter

To set-up a plasma arc cutter, simply hook-up the compressed air to the plasma
cutting unit. Three choices of air are available: bottled, an in-house air supply or a
small air compressor. Most plasma units have a built-in 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. If the amperage is too high or your travel speed is too
slow, the material you are cutting may become hot and accumulate dross. 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.

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 pre flow air; the pilot arc will then 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.
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. This is because your travel speed is too fast, you have
insufficient amperage, or the plasma stream is directed at an angle.
At the end of a cut, angle the torch slightly towards the end of the cut or pause briefly
to completely finish the cut. The post flow air will continue for a short period of time
after the trigger is released to cool the torch and consumable parts, however cutting
can be resumed immediately.
PLASMA ARC CUTTER TOOLS

 Power cable that works for 210-220 volts

 The work table
 Torch with head cable
 Air supply regulator valve.

Source: "How to Use A Plasma Cutter - A Comprehensive Beginners Guide".

The plasma torch tip has several openings. These opening helps operate the torch.
(A) Shown how air keeps the torch to each side of the metal cool and keep the hot
metal form spattering. (B) Allows the air to enter when the arc struck between the
metal and the electrode s producing a pilot arc. When the tip is brought close to
gas, it produces a stiff constricted cutting arc. This delivers a high concentration
of heat to a very small area. See illustration above.

Safety
Proper eye protection and face shields are needed to prevent eye damage called
arc eye as well as damage from debris. It is recommended to use green lens shade
#5. OSHA recommends a shade 8 for arc current less than 300 A, but notes that
"These values apply where the actual arc is clearly seen. Experience has shown
that lighter filters may be used when the arc is hidden by the workpiece."[4]
Lincoln Electric, a manufacturer of plasma cutting equipment, says, "Typically a
darkness shade of #7 to #9 is acceptable." Longevity Global, Inc., another
manufacturer, offers this more specific table for Eye Protection for Plasma Arc
Cutting at lower amperages
 CURRENT 0-20A 20-40A 40-60A 60-80A
MINIMUM SHADE #4 #5 #6 #8

Leather gloves, an apron and a jacket are also recommended to prevent burns
from sparks and hot metal.
Working in a clean area free of flammable liquids, materials and gases is very
important. Sparks and hot metal from a plasma cutter can quickly cause fires if
they are not isolated from flammable objects. Plasma cutters can send hot sparks
flying up to 5 feet away in certain situations. The operator of the machine is
typically blind to any fire that has started because they are behind their face
shield. Take safety precautions to make sure your work area is free of fire hazards.

ACTIVITIES

ACTIVITY NO.1: Draw Plasma Cutting Machine and label each part

ACTIVITY NO.2
ESSAY: If you are given a time to choose what cutting process are you going to
use? Oxy-acetylene cutting or Plasma Cutting? why?
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 WRAP–UP

PLASMA CUTTING MACHINE

Use the checklist below as basis for judging Whether you meet the required
competency. Mark check in the space provided.

Performance Indicators YES NO

1. Can identify the different parts of Plasma cutting machine?
2.Can connect the different fitting and cable of plasma cutting
machine?
3.Can check all part of the damage.
4.Can attach torch package correctly
5.Can attach flow valves and hoses to the gas’s outlet
6.Can install the cutting tip
7. Can set the amperage, or heat, of the cutting unit to the
proper level,
8. Press the trigger to initiate the pre flow air

9. Can operate properly the plasma cutting machine

Note: Have learners assess their performance. For criteria needing assistance,
provide the appropriate intervention/s

VALUING

Safety procedures must be closely followed in any application of the plasma

cutting machine. What precautionary measure you should consider in using plasma
cutting machine?
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 POSTTEST

Directions: Encircle the letter of the correct answer in every items.

_____1. What is the first step to set-up a plasma arc cutter?

a. Adjust the amperage down according to your travel speed
b. Angle the torch slightly towards the end of the cut or pause briefly to
completely finish the cut
c. Press the trigger to initiate the pre flow air
d. Simply hook-up the compressed air to the plasma cutting unit

_____2. What is the recommended distance to isolates flammable materials from

the sparks and hot metal from a plasma?
a. 1 foot away certain situations.
b. 3 feet away certain situations.
c. 4 feet away in certain situations.
d. up to 5 feet away in certain situations.

_____3. Leather gloves, an apron and a jacket are also recommended to prevent
burns from sparks and hot metal.
a. Leather gloves
b. Welding helmet
c. Safety goggle
d. Safety shoe

_____4. This is the recommended Number of green lens shade to use during
plasma cutting
a. #4
b. #5
c. #6
d. #8

_____5. This is a process that cuts through electrically conductive materials by

means of an accelerated jet of hot plasma
a. welding
b. Oxy-fuel cutting
c. Plasma cutting
d. Torches
 KEY TO CORRECTION
5. C 5. B
4. B. 4. D
3. A 3. A
2. D 2. C
1. D 1. C
POST TEST PRETEST

References
Government of the Philippines. DepEd-NCR Shielded Metal Arc Welding Module 1
series 2019
WeldGuru.com. 2020. Accessed June, 2020. https://weldguru.com/oxy-fuel-
cutting/

^ Jump up to:a b c d "What is CNC Plasma Cutting?". www.manufacturingnetwork.com. Retrieved 2015-11-

17.

^ "The life and times of plasma cutting". www.thefabricator.com.

^ "Making plasma cutting easier". www.thefabricator.com.

^ "Eye and face protection. - 1910.133". www.osha.gov. Retrieved 2015-09-27.

^ "How To Use A Plasma Cutter - A Comprehensive Beginners Guide".

^ Sacks, Raymond; Bohnart, E. (2005). "17". Welding Principles and Practices (Third ed.). New York:
McGraw_Hill. p. 597. ISBN 978-0-07-825060-6.^ see the online seller Amazon, for example

https://www.millerwelds.com/resources/article-library/tech-tips-for-better-plasma-cutting