Plasma arc cutting

Unit-III(B)
 Plasma arc cutting
• It is an arc cutting process wherein the
severing of the metal is obtained by melting a
localized area with a constricted arc and
removing the molten material with a high
velocity jet of hot, ionized gas issuing from the
orifice.
 Principle of operation
• Plasma arc cutting makes use of DCSP (electrode -ve) with a constricted transferred
arc struck between a tungsten electrode situated within the torch and the
workpiece to be cut.
• The cutting arc between the electrode and the workpiece is initiated by a pilot arc
established between electrode and nozzle.
• The nozzle is connected to ground (+) through a current limiting resistor and a pilot
arc relay contact.
• The pilot arc is initiated by a high frequency generator connected to the electrode
and nozzle. Ionized orifice gas from the pilot arc is blown through the constricting
nozzle orifice.
• This forms a low resistance path to ignite the main arc between the electrode and
the workpiece.
• Once the main arc is ignited the pilot arc goes off. A high-frequency electric arc thus
established is passed through a stream of inert gas (usually nitrogen) the latter is
ionized.
 Principle of operation
• Both the ionized gas column and the arc are forced through a small orifice
in the torch nozzle.
• The nozzle, having a relatively small orifice, constricts the arc and thus
increases current density and arc temperature.
• This high temperature arc is localized and concentrated upon a small area
of the plate where its intense heat melts the metal to the cut.
• The gas which is heated by the arc cannot expand due to the constriction
of the nozzle orifice and it emerges in the form of a supersonic jet.
• The base metal continuously melted by the intense heat of the arc is
removed by the jet-like gas stream (issuing from the torch nozzle) to form
a narrow kerf and smooth surface.
• The combined heat and force of the arc stream produce a high quality,
saw-like cut.
 Parameters involved in PAM
• Current: Up to 500A
• Voltage: 30-250V
• Cutting speed: 0.1-7.5 m/min.
• Plate thickness: Up to 200mm
• Power require: 2 to 200 KW
• Material removal rate: 150 cm3/min
• Velocity of Plasma: 500m/sec
• Material of workpiece: As previously stated, you can use any
metal as material of workpiece. For instance, aluminium and
stainless steel are highly recommended for this process.
 Applications of plasma arc
• 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 bevelling, 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.
 Advantages
• It cuts carbon steel up to 10 times faster than
oxy-fuel cutting, with equal quality more
economically.
• It leaves a narrower kerf.
• Plasma cutting being primarily a melting process
can cut any metal.
• Arc plasma torches give the highest temperature
available from many practicable sources.
 Disadvantages
• High initial cost of the equipment.
• This entire machining process consumes a high amount of
inert gases.
• Production of narrower surfaces takes place which is
unnecessary.
• The most harmful part of PAM is that metallurgical changes
takes place on the surface.
• The operator or person handling the whole process must
take proper precautions. This process can affect human eyes
so a proper googles or helmet must be worn by an operator.