4 Tips to Avoid Common Mistakes in Plasma Cutting

Date Posted:2 January 2023

No matter how proficient the operator is, errors can occur that harm cut quality and the length of time consumables last. The source of the problem usually lies with either the CNC system or the consumables. When dealing with poor plasma-cut quality or consumable life, it is recommended to troubleshoot. To reduce the risk of experiencing these issues, take a look at the tips provided in this article. Let's get started.

1. Guarantee Correct Gas Flow and Pressure

The gas pressure for the plasma torch needs to be set correctly for the best cut quality results. Too low gas pressure will cause the arc to be too weak to cut through metal, and too high gas pressure will make the arc unstable. To ensure the gas pressure is optimal, it is important to check the gas levels daily.

2. Match the Cut Speed to the Process

Incorrect CNC settings can significantly impact the quality of your finished product. If the cutting speed is too low, it can create a large, bubbly buildup of dross along the bottom of the cut piece and a widened kerf with a lot of top spatter. On the other hand, if the speed is too high, the arc can lag, resulting in a bevelled edge, a small and hard bead of dross along the bottom of the cut piece, and a narrow kerf. The right speed will give you a clean edge that requires little to no further work.

3. Align and Fit Parts Snugly Together

When installing consumables, it is important to ensure that they are put in the correct order and that the stackup is not too tight or loose. Poor electrical contact can result from incorrect installation and negatively affect the torch's gas and coolant flow. Additionally, dirt and grease should be avoided as this can reduce the life of the consumables and cause poor cutting quality.

To ensure the consumables are installed correctly, hands should be washed, and the consumables should be placed on a clean shop rag before being touched. For the best results, take the torch and all consumables to a clean room, such as an office, before beginning the installation process.

4. Ensure Correct Torch Height and Arc Voltage Settings

When setting up a CNC machine, it is important to consider both the pierce and cut heights. The pierce height is the distance between the torch and the plate when the arc is first struck. If it is too low, the torch may become covered in molten metal, while if it is too high, the arc will not transfer properly, and the consumable may be damaged. The cut height is the distance between the torch and the plate when the arc runs.

If it is too high, the arc may not reach the plate properly, creating a positive bevel. If it is too low, the arc may remove too much metal from the bottom of the plate, creating a negative bevel. The operator should also consider the wear of the consumable and adjust the torch distance accordingly to ensure proper operation.

Conclusion

Proper preparation is essential for successful plasma cutting. It is important to select the right nozzle, electrode, and shield cup for cutting material. Other important factors include pre-heat, post-heat, travel speed, and cutting amperage. One can avoid common mistakes and ensure a successful outcome by properly planning and preparing for a plasma-cutting project.

National Welding Supplies is a leading welding equipment supplier in Australia. We offer high-quality industrial tools and welding equipment that will suit all your welding requirements. If you’re looking for a reliable plasma cutting machine that does the job, we’ve got you covered. Browse our shop now!

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