PLASMA ARC CUTTING

(1)

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.

(2)

What is Plasma Cutting?

Plasma cutting is a process used to cut steel, stainless steel, and aluminum using a plasma torch. Put
simply, gas is blown at a high speed from a nozzle while an electrical arc melts the metal and
compressed air to blow away the molten metal.

Trainee performing plasma cutting

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 workpiece 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 workpiece. An electrical arc is then formed within
the gas, between an electrode near or integrated into the gas nozzle and the workpiece 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
workpiece. 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 workpiece.
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.

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 arc starts, not
cutting time.

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

Leather gloves, an apron and a jacket are also recommended to prevent burns from sparks and hot
metal.[5]

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.

7 advantages of Plasma Cutting

1. More Versatility

2. Ease of Use
3. Fast Cuts

4. Precision Cut Quality

5. Lower Price

6. Piercing Speed

7. Safety

Disadvantages

1. Most plasma cutters aren't useful for thicker or denser metals

2. relatively high power consumption

3.In the plasma cutting method, when cutting thick plates, the cut is V-shaped.

4.In the plasma cutting method, if the metal thickness is less than 5mm, it will cause a relatively large
amount of deformation during cutting. When cutting metal with a thickness of more than 30mm, a high-
power plasma power supply is required, and the cost is relatively high.

5.The plasma cutting method produces noise during cutting, dust, harmful gas, and arc pollution, which
will affect the working environment.

Video on plasma cutting

https://youtu.be/qd1L_9nljdg

https://youtu.be/ZcGPeM6A3G0