Mechanized Plasma Process Test Protocols

Contents

Introduction to plasma process protocols

Pierce test
Cut quality
Consumable life test
Cut quality over life
Definition of ISO9013
Methods for measuring cut quality over life
Variability with the use of ISO9013
Competitive examples

1 Copyright 2012, Hypertherm, Inc.

Introduction to Plasma Process Tests

A full validation of every process for every mechanized system is

conducted before launch
Each validation procedure takes 6-8 weeks per plasma process
Testing includes:
– Pierce
– Cut quality
– Life
– Cut quality over life

2 Copyright 2012, Hypertherm, Inc.

Pierce Test Protocol

A pierce test is conducted to determine maximum pierce thickness

Hypertherm’s
yp test requires
q p
piercing
g material 300 times
– If we successfully pierce 300 times, we pass the test and
move to the next larger thickness
– We repeat this process until we find a thickness that we can
not pierce 300 times
Cut quality must also be acceptable

HPR260XD HPR400XD

Pierce test successful on Pierce test successful on

1½” (38mm) 300 pierces 2” (50mm) 300 pierces

3 Copyright 2012, Hypertherm, Inc.

Pierce Test Process

How is the pierce test performed:

– Start by cutting three initial cut quality samples – set aside
– Perform
P f 100 pierces
i
– After 100 pierces, collect another three cut quality samples
• Take measurements (mass of electrode, nozzle and shield;
electrode pit depth)
• Note any observable damage to parts
• Inspect piercing plate sample to make sure all pierces
penetrated the bottom of the plate
• Note any torch misfires
– Repeat the test sequence for another 100 pierces; collect
another set of three cut quality samples
– Repeat again for a total of 300 pierces, cutting one more set
off three
h cut quality
li squares

4 Copyright 2012, Hypertherm, Inc.

Pierce Test Results

Definition of success after 300 pierces:

– No significant damage to nozzle/shield
– Acceptable cut quality after 300 pierces

Failure criteria:
– Arc transfer failure
– Electrode failure
– Unable to complete
p p
pierces
– Unable to cut

Image of SS plate after a completed

pierce test with the HPR400XD

5 Copyright 2012, Hypertherm, Inc.

Contents

Introduction to plasma process protocols

Pierce test
Cut quality
Consumable life test
Cut quality over life
Definition of ISO9013
Methods for measuring cut quality over life
Variability with the use of ISO9013
Competitive examples

6 Copyright 2012, Hypertherm, Inc.

Cut Quality: Consistency & Repeatability

8 hours / 1,400 meters of steel cut

Cut quality is much more prior to cutting these parts
th just
than j t th
the iinitial
iti l cut.
t It
is about consistency
throughout the life of the
consumables
Hypertherm conducts
rigorous internal life
testing to ensure
excellent repeatability
Example:
– 130A process on 10 10mm
– Less than .5mm edge deviation
(3.25° angle) after 900 20-
second cuts

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Cut Quality: Criteria

Edge deviation (angularity)

– Analyze all 4 sides
– Difference in angle from side to side (angle deviation)
– ISO range

Top edge rounding

Dross
– Mass of dross
– Dross free speed zone

Surface finish

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Angularity and Top Edge Rounding

PERFECT PART OVERLAYED ON CUT PART

Cut Angle
Top Edge Rounding

Copyright 2012, Hypertherm, Inc.

Measuring Angularity

5 points
i t on each
h side
id

CMM machine
hi

Consistency of all samples is measured on a high accuracy probe called a

Coordinate Measuring Machine (CMM)
5 or more points are measured that are used to determine a “best
best fit”
fit edge
All samples are then analyzed to determine variations from a “perfect square”

10 Copyright 2012, Hypertherm, Inc.

Edge Deviation and Tolerance
In the ISO specification, “u” equals edge deviation
Regions at the top and bottom of the cut are ignored
CMM measures at least 5 points, and takes the maximum distance = “u”
“u” is then used to quantify the cut edge in zones of quality from 1 to 5
(1 bbest,
t 5 worst)
t)

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Measuring Top Edge Rounding

To express top edge rounding, we

take a small probe and touch a
point .005” below the top (“T”)

We then look at where the best fit

line would have been and where
we intersect with the top edge
– Best fit line comes from
edge deviation
Edge measurement
provides best fit line

12 Copyright 2012, Hypertherm, Inc.

 Measuring Dross
Dross is the slag or molten waste that often solidifies
on the top or bottom of the plate
We use two ways y quantify
q y the dross p
performance of
a thermal cutting process Low Speed
– Size of “dross free zone” (DFZ) Dross

– Weight of dross in terms of micro-

grams/meter
High Speed
Dross

- Recommended Competitive System 2

HT2000 200A 1/4"

Cut Speeds
Competitive System 1
HT2000 100A 1/4"

HPRXD
HSD 130A 1/4"

50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
Cut Speed (ipm)

HyPerformance Plasma cuts with extensive dross free zones,

a key measure of process robustness

13 Copyright 2012, Hypertherm, Inc.

Contents

Introduction to plasma process protocols

Pierce test
Cut quality
Consumable life test
Cut quality over life
Definition of ISO9013
Methods for measuring cut quality over life
Variability with the use of ISO9013
Competitive examples

14 Copyright 2012, Hypertherm, Inc.

Consumable Life Test

The life curve is in all of our marketing literature

What does it reallyy mean?

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Consumable Life Test

One of the key differentiators that Hypertherm offers is the life of

our consumables

We test mild steel for a defined duration of cutting

g
Non mild steel life testing:
– Life tests only run to 1,080 20 second starts (all products, all
processes)
– Tests suspended after this as tungsten electrodes do not
wear significantly

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Consumable Life Testing

Range of life tests

4 second – Test of ramp-up and ramp-down – cut squares every 600
20 second – Simulated cut cycle – cut squares every 180
60 second – Test for steady state cathode erosion – squares every 60
30 minute continuous cut – Test for consumable temperatures

Life robustness testing is also completed “20/20” test”

20-second cuts with 20% ramp-down errors (simulates running
the arc off of the plate every 5th start)
Cut squares taken every 180 starts

Failure criteria
Electrode blow out
Cut quality failure (> ISO zone 5 ( 9o)) Image of plate after
Visual cut quality failure (rough edges, heavy dross) a completed life test
g difficulty
Starting y ((failure to transfer,, no p
pilot arc….))

17 Copyright 2012, Hypertherm, Inc.

Why Complete a 20/20 Test?

1620 starts with 20/20 1800 20 sec starts

It is a stress-based approach:

• Ramp down error produces

more deposits in the nozzle and
more electrode erosion

• Allows us to simulate worst-

case field conditions in the
l b
laboratory

18 Copyright 2012, Hypertherm, Inc.

Consumable Life Lab Test Protocol
1st 180 360 540 720 900 1080 1260 1440
A lot of sample Piece Starts Starts Starts Starts Starts Starts Starts Starts
squares are cut

Consumable Set
#1

Consumable Set
#2

Consumable Set
#3

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Life Test Results

Engineering compiles the average life data for all three tests
Marketingg then uses the 20/20 stress test results to “de-rate” the
life curve to better estimate production life expectations

20 Copyright 2012, Hypertherm, Inc.

Contents

Introduction to plasma process protocols

Pierce test
Cut quality
Consumable life test
Cut quality over life
Definition of ISO9013
Methods for measuring cut quality over life
Variability with the use of ISO9013
Competitive examples

21 Copyright 2012, Hypertherm, Inc.

ISO9013 Standards

ISO9013 is an international standard that evolved from a previous

German DIN2310 quality specification

Primary purpose is to provide a standardized way to measure thermal

cut quality and defines:
– Key parameters
– Geometrical definitions
– Quality zones

ISO9013 does not provide sufficient practical guidance on how to

measure p part q
quality
y
– Some general guidance on measurement instruments, but little
that can be implemented quickly and with no comments on
measurement accuracy
– It does give some general guidance on quality of laser, plasma,
and d oxyfuel;
f l h however, some off thi
this d
data
t hhas since
i b
become
outdated, and can be misleading

22 Copyright 2012, Hypertherm, Inc.

ISO Standard
ISO 9013 Zone Chart
Angularity v. Thickness
Thickness
0 0.5 1 1.5 2
(in)
100 100

10 10
(degrees)
Angle

Zone 5

Zone 4

1 1
Zone 3

Zone 2

Zone 1
0.1 0.1
0 10 20 30 40 50 60
Thickness
(mm)

As thickness increases, angularity decreases

23 Copyright 2012, Hypertherm, Inc.
ISO Zones of Edge Deviation Quality

The ISO specification is an alternative to angle measurement

It measures the deviation in the shape of an edge from a “perfect” square
Results are categorized into different quality ranges from 1 to 5 with 1
being the best quality

Thi k
Thickness Angle degrees

Range 2 Range 3 Range 4

Plate ISO Angle ISO Angle ISO Angle

Thickness deviation (degree) deviation (degree) deviation (degree)
(mm) u (mm) u (mm) u (mm)
6 0.19 2.04 0.46 4.87 0.92 9.67

10 0 22
0.22 1 43
1.43 05
0.5 3 25
3.25 1 00
1.00 6 48
6.48

15 0.26 1.12 0.55 2.42 1.10 4.84

25 0.33 0.85 0.65 1.69 1.30 3.38

24 Copyright 2012, Hypertherm, Inc.

Cut Quality Over Life
1st 180 360 540 720 900 1080 1260 1440
3 cuts per interval Piece Starts Starts Starts Starts Starts Starts Starts Starts
x 4 sides = 12
data points Run consumables
to failure

Consumable Set
#1
( Bevel angle
measured and
recorded on all 4
sides

Max angle used to

determine ISO range

Cut duration was

Consumable Set 20 seconds with
#2 20% ramp-down
errors

Consumable Set
#3

Total of 36 data
25
points
(

Copyright 2012, Hypertherm, Inc.

Example Data Set with Analysis

Data below is from 3 tests after 720 20-second cuts = 36 data

points
u1 u2 u3 u4
0.241 0.102 0.306 0.192
0.235 0.109 0.347 0.161
Summary
0.283 0.137 0.345 0.208
0.285 -0.171 0.335 0.242 Starts u Avg. u Dev. u Max. u Min. ISO Range
0.296 -0.193 0.335 0.302
720 0.218 0.142 0.353 ‐0.193 3
0.303 -0.189 0.328 0.332
0.312 0.153 0.312 0.225
0.276 0.201 0.316 0.201
0.235 0.218 0.352 0.230

Everyy angle
g of every
y side of every
y square
q is used to determine the ISO
range

26 Copyright 2012, Hypertherm, Inc.

Variability in the Use of ISO9013

Thickness & duration of cut

Angles observed
– A
Average
or
– Largest (worst) angle
Use of the guidelines
– Guidelines
G id li open tto iinterpretation
t t ti
– Varies by manufacturer

For ISO ranges, Hypertherm presents the data for the

Largest (worst) angle observed
We do not present average angle
– Too wide a spread
p to p
present average
g
– Any range can give you an average
– Largest angle gives you a better perspective on the cut quality you can
expect

27 Copyright 2012, Hypertherm, Inc.

Example: 10mm (3/8”) Material, Multiple

Average angle = 1.323 (add all sides and divide to get average)
ISO Range 2 if average angle used (1.323 > 0.52 and < 1.43)
Largest angle observed = 2.284 degree
ISO Range 3 if largest angle observed (2.284
(2 284 > 1
1.43
43 and < 3
3.25)
25)

ZONE DEVIATION (in) ANGLE (deg)

1 .003 0.52

2 .009 1.43

3 .020 3.25

4 .039 6.48

5 .065 9.99

28 Copyright 2012, Hypertherm, Inc.

Reading the Charts

The angle given is the HIGHEST point in the range

Plate Range 1 Range 2 Range 3 Range 4 Range 5

Thickness
(mm)
6 0.72 2.04 4.87 9.67 14.63

10 0.52 1.43 3.25 6.48 9.99

12 0.49 1.34 2.98 5.94 9.20

15 0 42
0.42 1 12
1.12 2 42
2.42 4 84
4.84 7 56
7.56

25 0.33 0.85 1.69 3.38 5.39

EXAMPLE:
For 10mm (3/8”) 3.25O is the highest end point of range 3. An angle greater than
3.25O becomes range 4.
For 10mm (3/8”) 2 25O is > 1
(3/8 ) 2.25 43O but < 3.25
1.43 3 25O; therefore range 3

29 Copyright 2012, Hypertherm, Inc.

How Competitors May Interpret the Charts

Some competitors read the angle as the LOWEST point in the range

Plate Range 1 Range 2 Range 3 Range 4 Range 5

Thickness
(mm)
6 0.72 2.04 4.87 9.67 14.63

10 0.52 1.43 3.25 6.48 9.99

12 0.49 1.34 2.98 5.94 9.20

15 0 42
0.42 1 12
1.12 2 42
2.42 4 84
4.84 7 56
7.56

25 0.33 0.85 1.69 3.38 5.39

SAME EXAMPLE:
For 10mm (3/8”) 3.25O is the lowest end point of range 3. An angle greater than
3.25O but less than 6.48 is range 3.
F 10mm
For 10 (3/8”) 2 25O is
2.25 1 43O but
i > 1.43 3 25O; therefore
b t < 3.25 th f range 2

30 Copyright 2012, Hypertherm, Inc.

HPR400XD Cut Quality Over Life

Notice the
duration of
time Angle range

Thickness of
plate

Hypertherm charts provide all relevant information to customers

Notice with thicker plate
plate, the variability in angles between ranges
becomes quite small

31 Copyright 2012, Hypertherm, Inc.

HPRXD Cut Quality Over Life
HyPerformance Plasma delivers HyDefinition cut quality with greater consistency,
faster cut speeds and half the operating cost of competing technologies

32 Copyright 2012, Hypertherm, Inc.