Choosing plasma cutting consumables and other plasma cutter tips

Many users often have questions about cut quality and consumable selection, and if you open your plasma cutter's operator's manual, you'll find hundreds of pages of safety specifications, power supply and torch specifications, power requirements, parts lists, and troubleshooting tips. In addition, the middle section of the manual is arguably the best resource: detailed cutting charts with information on cutting mild steel, stainless steel and aluminum. The charts cover all the material thicknesses the system can cut; explain which consumables to use and current strengths; and provide settings such as kerf, torch-to-workpiece distance, initial piercing height, piercing delay time, and cutting speed and arc voltage.

Some materials have unusual metallurgical properties that may be due to the presence of unusual levels of carbon, silicon, manganese or other alloys. Changes in metal chemistry often result in the need to deviate from the recommended cutting speed or height to obtain optimum results. In these cases, it is best to start with the exact settings shown in the operator's manual and then fine-tune the cutting height and speed. Many of the problems you will find solutions to in the user's operator's manual.

Of course, in addition to what is listed in the owner's manual, here are six tips, hints, and rules of thumb to keep in mind when selecting consumables for cnc plasma cutting machine that will help you make better use of your plasma cutter.

1、 Plasma Cutter Tip1: choose the right plasma cutting consumables for your machine

2、Plasma Cutter Tip2: Setting Current Intensity with Plasma Cutting Consumables

3、Plasma Cutter Tip3: Know When to Use Shielded, Unshielded Consumables

4、Plasma Cutter Tip4: Use Proper Cutting Height

5、Plasma Cutter Tip5: Pay Attention to Perforation Height

6、Plasma Cutter Tip6: Arc Voltage Measurement When Plasma Cutting

1、 Plasma Cutter Tip1: choose the right plasma cutting consumables for your machine

The first and most important tip is to make sure you choose the right consumables for your system. This sounds like very simple common sense advice, but you'd be surprised how very many people accidentally pick up and install the wrong consumables. Many consumable parts look the same, so it's not surprising that this happens. Double-check to make sure the part number you select matches the part number shown in your system or operator's manual.

2、Plasma Cutter Tip2: Setting Current Intensity with Plasma Cutting Consumables

Amperage is usually not included in the cutting tables because the amperage you select should be based on the amperage of the nozzle. For example, if you are using a 45 amp nozzle, the system should be set to 45 amps.

An amperage setting that is too low will cause the torch to produce low energy density, which can create choking or prevent the plasma arc from fully penetrating the material. If the amperage setting exceeds the maximum amperage requirement of the consumable, the nozzle will wear out and fail quickly. In general, low amperage consumables and settings will give you better cut quality, while high amperage consumables and settings will allow you to cut faster.

In the case of 10-gauge steel, for example, if you want to cut parts with an 85-amp air plasma system and get the best cut quality, you should choose a low-amp consumable. However, if you want to cut faster, use the 85 Amp shielded wear parts specification in the chart and understand that these parts will have larger edge angles.

3、Plasma Cutter Tip3: Know When to Use Shielded, Unshielded Consumables

If your CNC cutting table is equipped with ohmic sensing circuitry and uses electrical contact between the shield and the material to determine the exact position of the surface, select shielded consumables. If your CNC machine does not have ohmic sensing, then you should choose unshielded consumables.

4、Plasma Cutter Tip4: Use Proper Cutting Height

Cutting height is the desired height that the CNC machine and height control should maintain once the machine starts cutting and moving forward. If the torch is approximately 0.005 inches higher than the recommended setting, expect angularity, wider cuts, slag, and possible warpage on thin materials. If the torch is moved closer than this setting, collisions with the material may occur. Additionally, there is a risk of metal splatter on the front of your fusible link assembly, which could affect your arc.

On a related note, it is a good idea to spray a water-based gas-shielded metal-pole arc welding (GMAW) anti-spatter spray on the tip of the torch after installing the consumable. This will help prevent metal fragments and molten metal from sticking to your consumables, or at least make it easier to remove anything that does stick.

5、Plasma Cutter Tip5: Pay Attention to Perforation Height

Achieving the correct piercing height is just as important as the correct cutting height in order to ensure a long service life for your consumables. If the height is too low, splatter blown back during the piercing process can damage the nozzle after a few starts. A piercing that is too high may result in too much guided arc and cause premature nozzle damage. The correct perforation height is one and a half to two times the correct distance from the torch to the workpiece.

6、Plasma Cutter Tip6: Arc Voltage Measurement When Plasma Cutting

The arc voltage measurement can be found in the Best Quality Settings and Production Settings columns of the cutting table and is the actual unit of measurement between the electrode inside the torch and the material being cut. The longer the plasma arc, the higher the arc voltage. Keep in mind that the voltage settings listed in the manual will provide the correct cutting height, assuming your consumables are new. If your consumables are a little worn, you may need to manually adjust this distance.

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