Finetuning a

Plasma cut
for optimum
cut quality
The Perfect Cut is Ideal
2

All customers cutting metal are looking for essentially the

same thing - THE PERFECT CUT. The perfect cut would have
the following properties:

•Square angle •Low cost

•Excellent tolerance •No metallurgical
changes
•No kerf
•Repeatability
•High speed
The optimal Cut
3
•Near-square angle Choosing, the right cutting process,
optimized variables and undamaged
•Excellent tolerance consumables
•High speed Trading in quality for higher speeds

•Low cost Trading in surface quality for low cost

•Minimal metallurgical
changes Selecting the right gas and cut speed

Use small nozzle result is lower speed

•Small kerf
Use proper periodical maintenance
•Repeatability procedures and operators who know
how to use the different settings
Variables
4

Standard results when using setup as per cut charts

Optimum results by finetuning the cutting process

Variables influencing the cut quality
• Speed / arc voltage
Reading the cut for adjustments
• Dross formation
• Hole quality
Process
Variables
Process Variables
6
Amperage Reading the Cut
Cutting Capacities Defined Best Cut
Gases Appearance
Purity Cut Charts
Flow rate Direction of Cut
Plasma Cut Symptom Diagnosis
- Air Dross
- Nitrogen - Low-speed Dross
- Argon-Hydrogen - High-speed Dross
- Oxygen - Top Dross
Shield Bevel
Torch Height - Bevel Problems
Pierce Height - Corrections
Cutting Height Kerf width
Torch Height Control Lag lines
Cutting Speed & Arc Voltage Reading Lag Lines
Cutting Circles
Amperage (current)
7
Amperes - Measurement of the electron flow (number
of electrons per second) in an electrical circuit.

• For a given thickness, speed is increased when current level is

increased.
• A higher current level usually results in less dross for a given
material thickness.
• A lower current level usually results in better edge quality and
squareness for a given thickness.
• Lower current consumables typically have a longer operating life
than higher current ones, especially when cutting with oxygen.
Cutting Capacities
System Material Type Max Cut Capacity Max Pierce Capacity 8
HD 3070 Mild Steel 12mm 12mm
All plasma cutting 100 AMP Stainless Steel 12mm 12mm
Aluminum 12mm 12mm
systems have a
maximum recommended HD4070 Mild Steel 25mm 25mm
200 AMP Stainless Steel 19mm 19mm
cut capacity and pierce Aluminum 19mm 19mm
capacity. Pierce capacity
MAX 200 Mild Steel 50mm 25mm
is typically ½ of 200 AMP Stainless Steel 50mm 22mm
maximum capacity. Aluminum 50mm 22mm

HT 2000 Mild Steel 50mm 25mm

200 AMP Stainless Steel 50mm 22mm
Aluminum 50mm 22mm

HT 4001 Mild Steel w/O2 32mm 25mm

400 AMP Mild Steel w/N2 75mm 25mm
Stainless Steel 75mm 25mm
Aluminum 75mm 25mm

HT4400 Mild Steel 50mm 32mm

400 AMP Stainless Steel 50mm 25mm
Aluminum 50mm 25mm
Gases: Purity
9
Purity - It is essential that the following gases be
delivered to the plasma system in the listed levels of
purity. Failure to do so could result in poor cut quality,
poor consumable life, and overall degradation in system
cut performance.
• O2 and N2 with oxygen processes: 99,95
• N2, & H35 with inert processes: 99.995% pure
• Air: clean, dry and oil-free
• Methane: 93% pure
Gases: Flow Rate
10
Supply Pressures
• Gas consoles have a specified inlet pressure
requirement/flow rate for proper operation.
• It is recommended to have reliable regulators close to
the inlet ports to the gas console.
• Regulators should be of high quality (2-stage) and sized for
rated pressure and flow rate specified in the plasma arc
cutting system manual.
• The operator should monitor them often to determine that
the pressure and flow requirements are satisfied.
Gases: Selection
11
Considerations
• Type of material that is being cut
• Mild steel
• Stainless steel
• Aluminum
• Etc.
• Cut quality expectations
 Gases: Plasma Gas
12
The Plasma gas (red below) is the gas utilized to cut materials (cutting gas).

Plasma Gas - Also

called the cutting
gas. Gas that is
ionized in the
plasma process,
exits through the
nozzle orifice.
•Air
•Oxygen
•Nitrogen
•Argon-Hydrogen
Plasma Gas: Air
13
Advantage
• Good economical choice
• Readily available
• Good cut quality on carbon steel

Disadvantage
• Metallurgical changes in cut edge (weldability, formability, and
machineability on carbon steel)
• Consumable parts life is acceptable.
• Increased dross and surface nitriding
Plasma Gas: Nitrogen
14
Advantage
• Best cut quality on aluminum and stainless steel (when used in
conjunction with Water Injection)
• Excellent consumable parts life

Disadvantage
• Metallurgical changes in cut edge (weldability, formability, and
machineability on carbon steel)
• Increased dross and surface nitriding
Plasma Gas: Argon-Hydrogen
15
Advantage
• Primarily used when cutting stainless steel above 6mm thick
• Smoother and brighter surface finish
• High powered cutting applications (up to 1000 amps and up to 150mm
thick)
• Excellent consumable life
• It is used with dual gas systems to improve cut quality on stainless
steel from 9mm to 50mm.

Disadvantage
• Higher operating cost due to gas expense
• Rough cut edge on aluminum
Plasma Gas: Oxygen
16
Advantage
• Best choice for cutting mild steel
• Faster cutting speeds
• Exceptional edge quality
(angularity, smoothness, and minimal dross)

Disadvantage
• Increased operating cost (gas consumption & consumable life)
Gases: Shield Gas
17
The shield gas (green below) is used to shield the cut area from
atmosphere, producing a cleaner cut edge.
• Secondary gas in the
plasma process
• Surrounds the arc, and in
some torches assists in
arc constriction
• Further assists in nozzle
cooling
• Creates an atmosphere
around the cut edge
devoid of oxygen
• Shield gas is dependent
on choice of plasma gas
Torch Height: Piercing & Cutting
18

• Pierce height is the initial

height of the torch from
the plate when piercing.

• Cutting height is the torch-

to-work distance
maintained during a cut
cycle.
Arc Voltage Height Control
19

• Arc voltage height control monitors circuit voltage and adjusts

height of torch accordingly.
• Height of torch affects bevel angle and overall quality of the cut.
• Arc voltage height control maintains standoff on uneven plate.
Cutting Speed and Arc Voltage
20
As cutting speed increases arc voltage decreases and vice versa.

Cutting speed changes:

• When going in and out of corners
• At beginning and end of a cut
• When cutting circles and contours
• This will cause dross in corners and
contours
Reaction of THC:
• Torch will dive as speed decreases
• Torch will raise as speed increases
• THC must be turned off or ”AVC
Disabled” when speed decreases. This
is a required output of the CNC control.
Correct Cut Speed
21

Amperage correct for material “sweet spot” is

in the mid-range of cut chart
Speed correct; arc lagging slightly
Standoff correct; voltage dialed in
Appearance of Cut
22
• When cutting metals besides mild steel with oxygen, lag lines are
not a good indicator of cut speed.
• Bevel angle, dross levels and appearance of the cut must be
factored together. The smoothness or roughness of the face and
the dross levels will determine correct speed.
• Concave cut face is due to torch standoff being too low or
consumables are worn.
• Convex cut face is due to torch standoff being too high or
consumables are worn.

Good quality Stainless Steel Cut Good quality Aluminum Cut

Using Cut Charts
23
The cut charts give parameters
needed to set-up the system to cut.
• Flow rates should be adjusted
according to chart charts
• unless additional notes section gives
tips on adjusting to improve cut
quality
• It may be necessary to adjust Travel
Speeds and Torch-to-Work
Distance/Arc Voltage settings to
optimize cut quality and system
performance.
 Purge gases for at least 1 minute after
changing consumables and before
cutting.
Direction of the Cut
24

Clockwise: Cutting outer boundary of part. Part falls out.

Counter-Clockwise: Cutting inside hole. Scrap falls out
Symptom Diagnosis: Dross
25

Dross is material that is not fully ejected from the kerf. It can
take 3 forms:

• High speed dross: A small hard bead of uncut material.

• Low speed dross: A large bubbly accumulation along
the bottom of the cut.
• Top spatter dross: A light spatter that collects on top of the plate.
Low-speed dross
26

Globular dross that forms in large deposits. Comes

off very easily, in large pieces.
Cause: Eliminate By:
• Amperage too high • Use a smaller nozzle
• Speed too low • Increase speed
• Standoff too low • Raise voltage
High-speed dross
27

Fine roll-over dross that welds to bottom edge.

Cleaning requires chipping or grinding.
Cause: Eliminate By:
• Blown nozzle • Replace nozzle
• Amperage too low • Use larger nozzle
• Speed too fast • Slow down
• Standoff too high • Lower voltage
Top Dross (Spatter)
28

Top Dross or Spatter

appears on the top
edge of both pieces of
the plate. Lower the
voltage in increments
of 5 volts (maximum)
until top dross
disappears. Top Dross
is usually only seen
with Air plasma.
Lag Lines
29

Lag Lines
These are the ripples on the cut face or surface. The more
consistent the power produced by power supply is, the
smoother the cut. Depending on the process, normal lag
lines are curved and slanted at about 15° with proper
speeds.
Reading Lag Lines
Using the lag lines of a cut is an excellent way to determine proper 30
cut speeds.

• When the lines are more vertical the

speed is too slow.

Too Slow

• When the lines are more trailing the

speed is too fast.

Too Fast

• The lines should generally trail the

cut by approximately 10 -15 degrees.

Correct Speed
Bevel Angle
31
Bevel angle is the angle
of the cut edge with
respect to vertical. If the
cut is perfectly straight, it
has a 0 degree bevel.

Typical bevel is < 4

degrees around 4 sides
of a square.
High standoff = + bevel
Low standoff = - bevel
Bevel Angle Problems
32
Excessive bevel angle
• Nozzle damaged
• Torch not square to
material
• Torch travel direction (or
swirl ring spin direction
incorrect)
• Amperage too high/low for
material
• Stand-off too high/low
• Speed too fast/slow
Bevel Angle
33

Effect of torch height

on bevel angle

Negative Bevel Too Low

Zero Bevel

Positive Bevel Too High

Bevel Angle – Oxygen vs. Nitrogen
34
• An oxygen cut edge is squarer and the dross formation
is minimal compared to a nitrogen cut edge.
• Oxygen plasma also provides a metallurgically cleaner
edge that allows for better weldability, formability, and
machineability of the cut part.
Symptom Diagnosis: Kerf Width
35
Kerf is the void created by
the cutting process (or the
volume of material
removed).
Kerf width is important to
the dimensional accuracy
of the part.
Kerf width = 1.5-2.0 x
orifice diameter.
Slower speed=wider kerf
More power=wider kerf
Kerf compensation setting
Cutting Holes
36

• Rule of thumb - The

diameter of the circle
should not be less
than twice the
thickness of the
material.
• Cutting smaller holes
will produce a
tapered cut edge.
Cutting around Corners
37

A B

B‘

A‘ A‘
On top of the work the At the work bottom the
arc moves rectangular arc goes at the same
from A to B time from A‘ to B‘

This means the corner (marked red) is cut off

Consumable Check
38
Any attempt to get acceptable results with damaged
consumables is useless, so check them frequently

• The nozzle/shield bore has to be round including the outer

or inner bore edge – no damage or missing copper. No
inner deposits (oxide etc.) – this will also deflect the arc
• Fine swirl ring bores shall all be open, the ceramic not
cracked or damaged
• Up to 0,5-1mm wear on the electrode will not cause larger
effects
• In many applications both nozzle and electrode are worn at
the same time- so exchange both
• Use always a slight film of O-ring crease
Troubleshooting 39

Plasma Cutting
Consumables
What is wrong?
40

PROBLEM: Nozzle orifice is enlarged or distorted.

External face of nozzle shows depression surrounding
orifice.
What is causing it?
• Excessive pilot arcing
Solution:
• Verify proper pierce height
• Ensure good contact between
the plate being cut and work
cable.
What is wrong?
41

PROBLEM: A severe gouge in the nozzle may be visible

near the orifice. Usually poor cut quality is evident
shortly after replacing consumables.
What is causing it?
• Low plasma gas flow.
Solution:
• Verify proper gas flows.
• Inspect all gas lines and fittings
for leaks.
• Verify that no gas lines are
pinched or kinked.
What is wrong?
42

PROBLEM: Internal side of the nozzle shows pitting or

erosion of the copper, usually in a swirling pattern.
External face of nozzle may also show some erosion of
copper.
What is causing it?
• Double arcing or piercing too close
to the plate.
Solution:
• Verify proper pierce height.
• Verify proper settings for gas flows.
• Verify machine motion delay is not
too long.
What is wrong?
43

PROBLEM: Nozzle orifice is enlarged or distorted.

External face of nozzle shows depression surrounding
orifice.
What is causing it?
• Low injection flow.
Solution:
• Verify proper pierce height.
• Ensure good contact between
plate being cut and work
cable.
• Check injection water setting
What is wrong?
44

PROBLEM: Excessive build-up of material being cut

is present and attached to the shield.

What is causing it?

• Double-arcing or piercing too
close to the plate.
Solution:
• Verify proper pierce height.
• Verify proper cut speed and gas
flows.
• Verify that the pierce delay is not
too long.
What is wrong?
45

PROBLEM: Darkened area around the internal region of

the orifice, also visible on exterior face, shows an even
erosion of the copper surrounding the orifice.
What is causing it?
• Plasma gas restriction.
Solution:
• Verify proper gas flows.
• Verify that no gas lines are
pinched or kinked.
What is wrong?
46

PROBLEM: This torch displays a pitted current ring or

nozzle seat.

What is causing it?

• Dirty torch or consumables.
Solution:
• Always clean the torch when
changing consumables.
• Ensure that new consumables are
clean.
• Ensure the retaining cap is
properly tightened.
What is wrong?
47

PROBLEM: This torch displays signs of plasma gas

starvation. The internal Vespel is burned, and the worst
damage is directed toward the plasma gas inlet to the
torch body.
What is causing it?
• Insufficient gas flow.
Solution:
• Verify proper gas settings at gas
console.
• Check for flow restriction in gas
system or supply.
Consumables - Electrode
48

Electrode after Electrode after

normal use excessive use
Ensuring
Optimum
System
Performance
Coolant System
50
Coolant System
51

• If plasma system has a

built-in coolant system,
inspect filter element
located at rear of power
supply. Perform coolant
flow test at the return line
insuring flow meets
factory specifications.

Are fans running?

Torch Main Body
52

• If torch contains a water inlet tube for

electrode cooling, ensure that tube is
straight and has no pitting on the end.
Also make sure it is securely
screwed into the torch main body.
• Check torch current ring. It should be
smooth and not pitted. Clean ring
with cotton swab and water (do not
use alcohol).
• Inspect the Vespel torch insulator for
cracks. Replace torch main body if
cracks are found.
Checking the Torch Main Body
53

• If a torch main body has been

causing system to misfire, check
torch and lead set with a Meg-
ohm tester.
• Connect one probe to the (-)
green banded hose (electrode)
and one on the (+) pilot arc lead.
O-Ring Lubrication
54

• Inspect O-rings on the torch

body and consumables for
cracks and splits.

• Make sure that the lubricant

type is non-conductive and
that the correct amount of
lubricant is being applied to
the O-rings.
Torch Main Body
55

• Ensure that the retaining cap is

tightened securely to the torch
main body.
• Check all hose fittings at the rear
of the torch for wear. Ensure
these connections are tightened
correctly (damage to the fitting
threads may indicate over-
tightening has occurred).