CONTENTS

Title..............................................................................................1

Objectives....................................................................................2

Introduction.................................................................................4

Apparatus.....................................................................................5

Experimental procedure..............................................................7

Result and Data Analysis...........................................................10

Discussion of Results..................................................................11

Conclusions................................................................................13

Recommendations.....................................................................14

References.................................................................................15

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1.0 TITLE

Plasma Arc Cutting

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2.0 OBJECTIVES

 Define plasma cutting.

 Explain how air plasma cutting torch works.
 Explain how the flame cutting process works.
 Describe basic plasma cutting safety.
 Explain the air plasma cutting procedure.
 List the advantage and disadvantages of using a air plasma cutting torch

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3.0 INTRODUCTIONS

Plasma is an ionized gas that conducts electricity. Plasma is created by adding energy to an
electrically neutral gas. In this case, the gas is compressed air and the energy is electricity. The more
electrical energy added, the hotter the plasma arc becomes. Plasma arc cutting machines control this
powerful energy by constricting the arc and forcing it through a concentrated area (the nozzle). By
increasing air pressure and intensifying the arc with higher amperage, the arc becomes hotter and
more capable of blasting through thicker metals and blowing away the cuttings, with minimal
cleanup required.

3.1 BACKGROUNDS AND THEORY

Plasma is defined as a gas which has been heated to an extremely high temperature and ionized so
that it becomes electrically conductive. The plasma arc cutting and gouging processes use this
plasma to transfer an electric arc to the workpiece. The metal to be cut or removed is melted by the
heat of the arc and then blown away. While the goal of plasma arc cutting is severance of the
material, plasma arc gouging is used to remove metals to a controlled depth and width. In a plasma
cutting torch, a cool gas such as air or nitrogen (N2) enters Zone B (Figure 1-D), where a pilot arc
between the electrode and the torch tip heats and ionizes the gas. The main cutting arc then
transfers to the workpiece through the column of plasma gas in Zone C. By forcing the plasma gas
and electric arc through a small orifice, the torch delivers a high concentration of heat to a small
area. The stiff, constricted plasma arc is shown in Zone C (Figure 1-D). Direct current (DC) straight
polarity is used for plasma cutting, as shown in the illustration. The cutting torch also uses a
secondary gas (Zone A, Figure 1-D) which assists the high velocity plasma gas in blowing the molten
metal out of the cut and allowing a fast, slag-free cut. The secondary gas also cools the torch.
Compressed air, supplied by either a cylinder or plant air system, or CO2 is normally used as the
secondary gas. The plasma gas flows into the torch through the positive lead, around the electrode,
and out through the tip orifice. The secondary gas flows into the torch through the negative lead,
down around the outside of the torch liner, and out between the tip and shield cup around the
plasma arc. When the torch is started a pilot arc is established between the electrode and cutting
tip. This pilot arc creates a path for the main arc to transfer to the work. Because DC current alone is
not sufficient to initiate and maintain the pilot arc, high frequency is superimposed on the direct
current. DC power is also used for the main cutting arc. The negative output is connected to the

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torch electrode through the torch lead. The positive output is connected to the workpiece via the
work cable and to the torch through a contactor and resistor.

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4.0 APPARATUS

 Plasma Cutter

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1

3
2 4

1) Power supply
2) Control panel
3) Cutting torch
4) Earth clamp

Material Thickness,mm Gas Current, A Speed, mm/min

Mild steel ≈ 10 Compress air 90 ≈800

 Specifications

 Workpiece dimensions

100 mm

150 mm

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4.1 OTHERS APPARATUS

 CNC Plasma Cutter

-A specialized use of CNC Plasma Cutters has been in the HVAC industry. Software will
process information on ductwork and create flat patterns to be cut on the cutting table by
the plasma torch.

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5.0 EXPERIMENTAL PROCEDURES
 Sequence of Operation
Install & Put On Personal Check Torch Tip, Check Gas/Air Set
Connect Safety Electrode, And Pressure Controls
Equipment Equipment Retaining Cup

Begin Turn On
Cutting Power Source

 Cutting Operation
1) To begin cutting, place the tip of the torch on the work for drag cutting or from 1.5 mm to 3
mm form work for standoff cutting (Note: standoff cutting will increase the consumables life
and allow for faster cutting speeds).

2) When starting at the edge of a piece of work, start with the torch at a 90º angle to the work.

3) Pull the trigger and the arc will start immediately.

4) Slowly start moving the torch across the metal insuring that the sparks are going through the
metal. If sparks are not going through the cut slow the rate or the cut. Start cutting from the
edge of the workpiece.

5) For best results keeps the torch moving at a steady pace.

6) Finish the cut and release the trigger to stop the arc. (Note: Gas/Air will continue to flow for
20 seconds after the trigger is released).

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 Safety trigger operation

a)

b) Lifts trigger safety lock.

Press trigger.

c) Avoid firing the torch when it is not in

contact with the workpiece.

 Safety precautions
 ELECTRIC SHOCK can kill

· Install and earth the welding machine according

to the applicable regulations.
· Do not touch live electrical parts or electrodes
with bare skin, gloves or wet clothing.
· Isolate yourselves from both the earth and the
workpiece.
· Make sure your working position is safe.

 FUMES AND GASES can be hazardous

· Keep your head away from fumes.

· Work in the presence of adequate ventilation,
and use ventilators around the arc to prevent
gases from forming in the work area.

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 ARC RAYS can burn eyes and skin

· Protect your eyes with welding masks fitted with

filtered lenses, and protect your body with
appropriate safety garments.
· Protect others by installing adequate shields or
curtains.

 CUTTING can cause fire or explosion.

· Sparks (sprays) may cause fires and burn the skin;

you should therefore make sure there are no
flammable materials in the area, and wear
appropriate protective garments.
·Hot metal and sparks blow out from the cutting
arc. The flying sparks and hot metal, hot
workpiece, and hot equipment can cause fires and
burns. Check and be sure the area is safe before
doing any cutting.

 FLYING SPARKS can cause injury

·Sparks and hot metal blow out from the cutting

arc. Chipping and grinding cause flying metal.
· Wear approved face shield or safety goggles with
side shields.
· Wear proper body protection to protect skin.
· Wear flame-resistant ear plugs or ear muffs to
prevent sparks from entering ears.

 PLASMA ARC can injure

·The heat from the plasma arc is very intense and
forceful and can burn through protective clothing and
pierce skin causing serious burns.
· The pilot arc can cause severe burns, keep body away
from the cutting tip when the trigger is depressed.
·Always point the cutting tip away from your body
when trigger is pressed, the pilot arc comes on
immediately.
· Always wear protective clothing when operating the
cutter, cover all exposed body areas.

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6.0 RESULT AND DATA ANALYSIS
Figure (1) Figure (2) Figure (3)

Figure (4): Example of good result

 Common operating problems during cutting based on figure (1),(2) and (3)
 Poor consumable life  Cut is at an angle

a. Current too high for consumables a. Cutting tip worn

b. Poor air quality b. Air pressure incorrect or
c. Poor air pressure flow restricted
c. Travel speed to high
 Main Arc Extinguishes

a. Cutting speed too low

b. Standoff too high

 Dross Formation

a. Improper gas pressure

b. Improper cutting speed
c. Worn or damaged torch parts.

 Burned-Out Tips

a. High cutting current

b. Damaged or loose cutting tip
c. Tip in contact with work
d. Heavy spatter
e. Low plasma gas pressure

7.0 DISCUSSIONS OF RESULTS

 Compress Air is the most versatile plasma gas. It produces good cut quality and speed on mild
steel. Air also lowers the cost of operation because it is not necessary to purchase gases. For this
reason air plasma systems are not popular with gas suppliers. However air is not free. Shop air

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 must be cleaned to remove contamination such as particulate, oil mist, and moisture. The best
solution for air plasma systems is a good-sized, dedicated air compressor, a refrigerated dryer,
and a bank of filters to take out particulate, oil mist, and any remaining moisture. Another
concern with air plasma is weldability of the cut edge. Some nitriding and oxidation of the cut
surface occurs with air plasma; this can cause porosity in welds. The problem is usually corrected
by simply using good quality weld wire with denitriders and deoxidizers. For versatility, good
speed, low dross levels, and parts life up to 600 starts, air is a good option for many shops. Air
shield gas is the best choice when using air plasma.
 Advantages

-Cuts any type of electrically conductive metals including aluminium, copper, brass and stainless
steel.
- Cuts faster — up to 33.02 mm per minute on 0.0635 mm Steel.
-Does not require a pre-heat cycle which saves time and is more convenient
-Produces a small and more precise kerfs’ (width of the cut), great when precision matters
-Has a smaller heat affected zone which prevents the area around the cut from warping and
minimizes paint damage.
- Plasma cutting requires only minimal operator training. The torch is easy to operate, and new
operators can make excellent cuts almost immediately.
-Plasma cutting is more economical.
-Plasma cutting systems can yield quality cuts on both ferrous and nonferrous metals. Thickness
from gauge to 0.762 mm can be cut effectively.

 Disadvantages of plasma cutting

-Plasma cutting creates a large heat-affected zone in the area surrounding the cut.
-Cutting materials under-water cutting minimizes the size of the heat-affected zone.
-Dross, the resolidified metal that forms at the bottom of the cut, is a potential issue for processors
using plasma cutting since it frequently forms during plasma cutting.

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-High initial cost of the equipment
-The moving parts in the cutting head are subject to wear which adversely affects the quality and
accuracy of the shaping.

 Applications of Plasma Arc Cutting

- Plasma cutting is used to cut particularly those nonferrous and stainless metals that cannot be cut
by the usual rapid oxidation induced by ordinary flame torches.
-Plasma cutting can be used for stack cutting, plate beveling, and shape cutting and piercing.
- With some modifications, plasma arc cutting can be used under water.
- Plasma arc cutting finds applications in many industries such as shipyard, chemical, nuclear and
pressure vessel.
-It is used for removing gates and risers in foundry.
- It cuts hot extrusions to desired length.
- It is used to cut any desired pipe contour.
- It is also employed for gouging applications.
- It finds use in the manufacture of automotive and railroad components.

8.0 CONCLUSIONS

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9.0 RECOMMENDATIONS
 The automotive and construction industries use a computer numerical control (CNC) plasma
torch to make custom auto shapes required for chassis or frames, and to cut large steel beams.
The versatility and accuracy of this device makes it a great tool for the creating metal art,
jewellery and ornamental iron work. Many CNC torches are large, expensive equipment
designed to operate on the assembly line of a large shop, such as an automobile factory;
however, smaller and more affordable models are now available for small shops and individual
craftsmen.

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 For mild steel use oxygen plasma and air shield for the best cut quality, lowest dross levels,
minimal rework, excellent weldability and highest cutting speed/productivity.

 For best cut quality on stainless and aluminum under 0.127 mm use nitrogen plasma and air
secondary for a good balance of cut quality and affordability. For a slightly better and faster cut,
use CO2 as the secondary. If your system allows, water shield will provide the best edge quality.

 For best cut quality on thick stainless and aluminum use Argon-Hydrogen with Nitrogen
secondary. WARNING! Your system must be equipped for safe operation with argon hydrogen
gas.

 For most economical cutting, clean dry shop air is the best choice for mild steel, stainless, and
aluminum.

10.0 REFERENCES

1) http://www.wisegeek.com/what-is-a-plasma-torch.htm
2) http://www.welding-robots.com/articles.php?tag=634
3) http://www.teskolaser.com/metal_cutting.html#plasma
4) http://www.welding-technology-machines.info/thermal-cutting-of-metals/plasma-arc-
cutting.htm

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5) http://www.ehow.com/about_5333356_cnc-waterjet-vs-plasma-cutter.html
6) http://www.centricut.com/New_Lessons/lessons_9.html
7) http://www.welding-technology-machines.info/thermal-cutting-of-metals/advantages-and-
disadvantages-of-plasma-arc-cutting.htm

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