Metal Cutting

Plasma

Oxy Fuel
Plasma Arc Cutting (PAC)
is a cutting process that uses an arc and a high-velocity,
ionized gas coming through a nozzle to cut all metals that
can not be cut with flame
Such as:
Stainless steel
Aluminum
Copper
 PAC
Plasma is a super heated gas that is ionized.
Ionized- Electrons in the gas have broken away
form their atoms and will conduct electricity.
Gases used for plasma cutting includes:
Hydrogen
Argon
Nitrogen and mixture ,plus air and oxygen
 PAC
How it cuts
◦ The plasma gas (compressed air) is forced through a
nozzle and heated by the arc which reaches to 5,0000°F
 Advantages of PAC
Can cut all metals

Fast cutting speeds

Little distortion from heat

No hazardous gases

Oxygen based system do not leave nitride deposits

Nitrogen based systems are for aluminum, stainless

steel and nickel
 Disadvantages
Plasma Torch is expensive
Not portable (needs electricity)
Metal fumes created can be a health hazard
Puts tremendous heat into the metal around the cut
Creates HAZ
Hardens materials next to the cut
 Safety/ Maintenance
A minimum of a #9 filter shield should be used

Need proper ventilation to remove harmful gases

Dip electrode into anti-spatter compound

Do not allow Pilot Arc to continue for long periods

of time
 Setting the PAC Torch
If torch amps is set too high travel speed needs to be increased

Thickness Current Travel Speed

1/16” 35 amps 175 in/min
1/8” 40 amps 90 in/min
1/4” 40 amps 40 in/min
1/4” 80 amps 100 in/min
3/8” 40 amps 18 in/min
3/8” 80 amps 55 in/min
1/2” 40 amps 20 in/min
1/2” 80 amps 35 in/min
 How to Use
Clean metal
Hook up ground cable
Draw cutting pattern on metal
Hold torch 1/16-1/8” from metal (torch stand
will help maintain this)
Hold torch at a 70 to 90° angle
Pull button when arc begins pull torch
across metal
 Cutting Speed
Too Slow- Molten metal will collect on
bottom of work piece and need to be
ground off (this is called Dross)

Too Fast- Metal will not be cut all the

way through
Oxy-Fuel Cutting
 Oxy-Fuel Cutting, Welding
Definition:
Burningis the rapid oxidation of a material
Does Metal Burn?
◦ Virtually all materials will burn if they are first heated to
their ignition temperature.
◦ Steel ignition temp is when it is cherry red, 1300-1400° C
◦ Oxygen burns preheated metal and blows it away from the
work piece.
 Oxyacetylene welding (OAW)
Oxygen and acetylene gas are mixed in the torch tip. The mixture burns at the torch
tip.
The heat from this flame is used to melt the base metal and welding rod. This
melted material forms a weld joint.
OFC Equipment
Combination Cutting Torch with Cutting Attachment

Straight Cutting Torch

Cutting Tips
3690 Cutting Tip

3690-P Cutting Tip

 OFC Cutting Tip Information
CUTTING TIP SELECTION CHART
Thickness Tip Cutting Oxygen Acetylene Oxygen Acetylene
of Metal Size Orifice Pressure Pressure Consumption Consumption
in Inches Number Drill Size (P.S.I.G.) (P.S.I.G.) (SCFH) (SCFH)
Light gauge
to 3/16 000 #68 15-20 5-15 35-40 10-15
3/16 - 3/8 00 #64 20-25 5-15 45-50 10-15
3/8 - 5/8 0 #60 35-40 5-15 75-85 15-20
5/8-1 1 #56 35-40 5-15 97-107 15-20
1-2 2 #52 40-45 5-15 180-195 20-30
2-3 3 #48 45-50 5-15 270-290 20-35
3-6 4 #42 50-75 10-15 450-600 25-40
 Oxy-Fuel Cutting Set-up

All set up the same as oxy-fuel welding except:

◦ To set working pressure for oxygen must open cutting
valve
 Oxy-Fuel Cutting Process
Clean metal
Draw line
Make jig to keep cut straight
Hold tip 1/16-1/8” above metal
Preheat metal to cherry red color
Open oxygen valve and push torch through
metal
◦ (Angle tip slightly toward direction of cut)
Cutting Flame Types
Carburizing Flame

Neutral Flame

Neutral Flame with Oxygen Cutting Stream

Oxidizing Flame
Advantages
Can cut complex shape
Can cut carbon and low carbon steel
Inexpensive process
Can have multiple cutting torch
Disadvantages
It is slower than other cutting systems
Cut accuracy is not as good as plasma, water
jet ,laser
Creates heat affected zone