Here, I’ll tell you everything you need to know about using plasma cutters to cut stainless steel.

Can a Plasma Cutter Cut Stainless Steel?

Yes, a plasma cutter can cut stainless steel perfectly well.

Plasma cutting is versatile because it allows you to tweak the cutting settings closely according to the final result you want. You can choose from a wide variety of gasses for cutting, and some plasma cutters can even cut stainless steel up to 160mm thick.

Despite that, plasma cutting is on the cheaper side of the scale with it comes to cutting stainless steel. It’ll cost you less than laser cutting, for example.

How to Cut Stainless Steel With a Plasma Cutter

Cutting stainless steel with a plasma cutter involves making sure you have the right equipment, tweaking the settings, and choosing the right gas.

Here’s how to do all that.

Choose a Reliable Cutting System

The choice of your plasma cutting system mainly depends on your budget, but you also need to take the final result you want into consideration.

For example, cheaper air plasma systems will have limited cutting options. You’ll likely only be able to cut thinner plates–no more than 30mm thick. Also, air cutters will give you a dark finish because they only use air to cut. The nitrogen in the air will cause a black finish, and the oxygen will cause a choppy finish around the edges.

Most users will be okay with these downsides because air cutters are much cheaper, but if you want the best result, consider industrial CNC plasma cutters. 

Industrial cutters allow you to choose from various gasses, depending on the result you want (more on that below).

They also have a smooth, shiny finish and can cut much thicker stainless steel plates.

Select the Right Consumables

Before attempting to cut stainless steel with a plasma cutter, make sure you have the right consumables. It’d be better to check with your supplier first to know which ones you’ll need—because stainless steel often needs different consumables from other materials.

Selecting the right consumables doesn’t only ensure you get a smooth result, but also helps reduce dross, which can be a pain to clean because of its hardened state.

Choose the Right Gas

Choosing the right gas for cutting depends on whether you’re going for single-gas or dual-gas cutting.

Here are the common options for single-gas cutting:

• Oxygen: Oxygen isn’t the best option for cutting stainless steel because it ends up causing burnt edges and a choppy finish. However, it’s one of the cost-efficient options.
• Nitrogen: Nitrogen is a common choice for cutting stainless steel because it cuts at high speeds.
• Compressed air: Compressed air causes a black finish around the edges because of the high nitrogen content, so it’s not the best option, but it’s low-cost.

Dual-gas systems are highly versatile and are often the choice of professional cutters. Here’s an overview of the common options for cutting stainless steel:

• Hydrogen/Argon-Nitrogen: H35 and nitrogen are often selected for cutting stainless steel because they result in a square cut edge. However, they may result in more dross than other options.
• Nitrogen-Water: the nitrogen and water pairing is a cost-efficient one, although you’ll need a water table for it. It provides a smooth top edge.
• Hydrogen/Nitrogen-Nitrogen: this pairing’s use is limited because you can only use it to cut stainless steel plates less than ⅜ inches thick. However, it provides excellent angularity.

Adjust Advanced Controls

Some advanced piercing controls can make your life much easier when cutting stainless steel.

For example, some plasma cutters have a two-step pierce height control feature. When you enable this feature, the piercing starts at ¼ an inch before the torch retracts to its final height. That way, the torch returns to the final height until the piercing is done, which protects the nozzle from damage.

You won’t believe how fast these nozzles get damaged—unfortunately, I’m well familiar with the drill—, so if your cutter has this feature, it’d be wise to make use of it.

Some plasma cutters also have a diverter control feature, which blows the molten metal pieces away from the piercing area, thereby protecting the shield cap from damage.

Tips for Cutting Stainless Steel With a Plasma Cutter

If it’s your first time using a plasma cutter with stainless steel, you may need some tips to guide you. Here are some tips that may make your first time easier than mine!

When cutting painted stainless steel, make sure you have a solid ground connection as close to your cutting area as possible. The same goes if you’re cutting a particularly dirty stainless steel plate.

Opt for a slower cutting speed if you want a dross-free cutting process. Higher speeds are generally time-efficient, but they result in plenty of dross, which may be a pain to clean after you’re done. If you have no option but to use a high speed, keep it constant for the whole cutting process and ensure the stable working table.

Make sure to work in a safe area with appropriate filtration and fume extraction systems. Cutting stainless steel produces risky fumes that may lead to respiratory diseases if consumed in large amounts. Its fumes contain a lot of chromium, a toxic element known for causing cancer.

Final Thoughts

Plasma cutters are actually an excellent option for cutting stainless steel because they’re not as expensive as water jets or laser. Besides, they’re highly versatile and allow you to tweak the cutting settings accurately.

The gas you choose for cutting also plays a big role in how your cutting will look like. Most industrial cutters have dual-gas systems because they allow for better accuracy and smoother finishes.

The post Will Plasma Cutters Cut Stainless Steel? appeared first on Beginner Welding Guide.

Modern plasma cutters are designed to cut through most conductive metals, including aluminum, with relative ease. Current handheld cutting systems can slice through aluminum sheets up to 1 to 1.5 inches in thickness, while industrial systems can slice through aluminum up to 6 inches in thickness.

How to Use a Plasma Cutter to Cut Through Aluminum

Plasma cutters work by using a concentrated stream of superheated ionized gas to slice through conductive metals, such as:

• Mild steel: low-carbon steel commonly used in car fabrication
• Stainless steel
• Carbon steel
• Expanded steel
• Copper
• Brass
• Iron
• Aluminum

Compared to other conductive metals, aluminum has a lower melting point, presenting some unique challenges when cutting soft metal. An important factor in achieving a quality cut of aluminum is the gas mixture used in the system. 

Plasma cutters use two types of gas: a shield gas and a plasma gas. 

Plasma Gas Choices

Plasma gas is a gas mixture that’s concentrated and superheated at the nozzle to produce the cutting stream. Plasma gasses can be comprised of any of the following mixtures:

• Compressed Air (78% Nitrogen + 21% Oxygen)
• 99.5% Oxygen
• 99.9% Nitrogen
• H-35 (35% Hydrogen + 65% Argon)
• F5 (5% Hydrogen + 95% Nitrogen)

Each plasma gas differs in how the ionized gas particles interact with specific conductive metal particles. So to achieve the best quality cuts, you’ll want to keep in mind the ideal gas for the metal you’re working with.

For example, when cutting aluminum, nitrogen provides a cleaner and speedier cut than other plasma gasses.

In contrast, nitrogen is a less-than-ideal choice when cutting through mild steel; oxygen would give a cleaner cut.

Choosing a plasma gas is not the only important factor in getting a good quality cut; you also have to choose the right shield gas to pair with your plasma gas.

Shield Gas Choices

Shield gasses swirl and envelope the end of the nozzle and serve some important functions:

1. Cool the nozzle and the material to be cut, preventing overheating.
2. Blow away dust and debris from the surface to be cut.
3. Blow away molten metal to prevent it from getting in the way of cutting contact.
4. Prevent atmospheric air from oxidizing the cut
5. Focus the torch head

There are four gas mixtures commonly used as shield gasses:

1. Compressed Air (78% Nitrogen + 21% Oxygen)
2. 99.5% Oxygen
3. 99.9% Nitrogen
4. Carbon Dioxide (CO₂)

Plasma/Shield Gas Combinations for Cutting Aluminum

Some shield gasses pair better with specific plasma gasses, depending on the type and thickness of the metal to be cut. For aluminum cutting, the following combinations are often recommended, each with its own pros and cons:

The air/air combination is the most economical and readily available option, especially for general-purpose or home DIY projects. Some plasma cutter systems come with a built-in air compressor, eliminating the need for purchasing a separate air compressor and adapter. 

However, the air/air combination has a higher chance of oxidation during the cutting process, which can affect the quality of plasma welds done on the metal. When metal oxidizes, it will require a higher temperature to melt and manipulate. 

In terms of welding, oxidation can cause uneven welds, which negatively affects the weld’s visual presentation and structural strength. While this may not be an issue for home projects, you’ll want the cleaner, unoxidized cuts offered by nitrogen combinations for commercial use.

For aluminum thicknesses less than ½ inch, the air and nitrogen plasma combination can produce clean and speedy cuts.

However, when tackling aluminum thicknesses more than ½ inch thick, it’s best to opt for the H-35 (Argon-Hydrogen) combination, as it produces the hottest flame and smoothest cut compared to the other options.

Using H-35 on thinner cuts is possible, but the high heat produced can cause issues while cutting.

Plasma Cutter Consumables

Using a plasma cutter inevitably leads to wear and tear, as with any machine. Consumables are parts of the plasma cutter that must be replaced after repeated usage. 

Consumables include:

• Swirl Ring: causes the shield gas to constantly swirl around the plasma torch, keeping it focused and preventing the nozzle from overheating 
• Nozzle: the aperture where the plasma gas is focused through. Nozzles have different sizes depending on the type of cutting.
• Electrode: a thin piece of copper-hafnium that receives electric charge and arcs that charge onto the cut material
• Shield Cap: protects the nozzle from sparks and molten metal created during the cutting process.
• Retaining Cap: holds all the consumable parts of the plasma cutter together near the nozzle

It’s important to keep track of the condition of your consumables to ensure that your plasma cutter is performing optimally and to reduce the chances of any hazards. 

Refer to your machine’s maintenance manual for the proper parts information and instructions on replacing your consumables.

Conclusion

Modern plasma cutters are designed to cut through aluminum with the right combination of plasma and shield gasses.

Using filtered shop air as a plasma and shield gas is an economical and versatile choice for general-purpose use and home DIY projects, with a few caveats concerning oxidation and weld quality. 

Other plasma and shield gas options are available for cleaner and speedier cuts on aluminum but come with a higher expense.

The post Can You Cut Aluminum with a Plasma Cutter? appeared first on Beginner Welding Guide.

When you need to cut metal instead of weld it together, a plasma cutter is the best tool you can have on hand. A plasma cutter uses the power of plasma, the lesser-known fourth state of matter, to melt metal and cut it into pieces. If you’re unfamiliar with plasma cutters, you might wonder how they work.

Plasma cutters need gas because you can only create plasma by heating pressurized gas until it enters a plasma state. Thus, you have to have a reliable gas supply on hand if you use a plasma cutter. 

Here is everything you need to know about why plasma cutters need gas, including the best type of gas to get.

Do Plasma Cutters Need Gas?

Yes, plasma cutters need gas. Without gas, you are missing the most important component of a plasma cutter—the plasma itself. Plasma is superheated gas that consists of positively and negatively charged ions. 

To understand why you need a gas canister for your plasma cutter, you need to know how these machines work. Plasma cutters create plasma by heating pressurized gas using a negatively charged electrode. The gas is forced past the electrode in a narrow channel, putting it under even more pressure and speed until it changes into plasma. Then, the charged plasma bonds to the metal, creating a complete electrical circuit.

Plasma cutters need a lot of gas to work because you both need enough gas to turn into plasma and more gas to use as a shielding material during the welding. Without gas, a plasma cutter wouldn’t be able to function at all. If you use a plasma cutter in your workshop, ensure you always have an extra gas canister handy.

What Gas Does a Plasma Cutter Use?

Plasma cutters can use several different gases to do their jobs. Here are the most common ones as well as their different properties. Using the right gas can help you learn how to use a plasma cutter.

1. Compressed Air

If you’re running a DIY plasma cutter in your backyard workshop, the easiest gas to use for your plasma cutter is compressed air. You don’t even have to go out and buy this gas because you have a free supply of air no matter where you look! 

You will have to invest in an air compressor or a plasma cutter with an attached air compressor, but after that initial investment, you won’t have to buy gas again. 

Compressed air seems like it isn’t that special, but it is actually very effective once you run it through a plasma cutter. It can cut smoothly through steel and aluminum. 

However, compressed air is not perfect for industrial uses because it is not as powerful as other gases. It can only cut through metals that are up to one inch thick. Plus, oxidation is more common with this type of gas, which is less of an issue for an at-home project but will affect the quality of the weld on an item you are selling.

2. Oxygen

Another very common gas for plasma cutters is oxygen. Oxygen is the most common gas in plasma cutters because it is the fastest and acts as a built-in shielding gas. It also has the best quality cut, especially for materials such as steel. It works with metals as thick as 1¼ inch. 

However, oxygen is also the most expensive gas. You are saving money by ensuring every cut is high-quality, but if you use your plasma cutter a lot, you may look at other options for lowering costs.

3. Nitrogen

Nitrogen is very similar to oxygen because it also creates very high-quality cuts. Although it is slower than oxygen, it is effective, especially when working with aluminum and stainless steel. It is more durable than oxygen and works well in tandem with other gases such as CO₂ and argon.

Nitrogen is the best choice for cutting thicker metals. A high-current plasma cutter and nitrogen combination can cut metals up to three inches thick. 

The only downside is that nitrogen is also pricey, so if you don’t need such a high-powered cut, it’s not worth buying it.

4. Argon-Hydrogen

This mix of gas usually uses 65% argon to 35% hydrogen. Argon-hydrogen is the most powerful gas for plasma cutters, creating a plasma that is hot enough to cut through metals up to a whopping 6 inches thick. It also produces a very smooth cut, making it perfect for plasma gauging, not just cutting.

However, the same qualities that make argon-hydrogen a good choice in some jobs are its downfall in other situations. The high heat is perfect for cutting through thick stainless steel but will damage softer metals such as mild steel. For smaller jobs, the cost of argon-hydrogen is not worth it.

How to Choose the Right Gas

There are four main gases you can use for your plasma cutter. 

To choose the right one, you must consider the metal you are cutting. If you are working with 6-inch-thick pieces of stainless steel, you need argon-hydrogen, which will be too much for a simple sheet of aluminum. 

Also, look at the type of metal you are working with, as different metals react better with different combinations of gas and shield gas.

Another important factor is your budget. While oxygen and nitrogen produce clean, smooth cuts, you can get just as good results with compressed air for a fraction of the price. 

Equipment Needed

To operate your plasma cutter, you need some equipment on hand, including the following:

• An air compressor (only if you are using compressed air to power your plasma cutter)
• Gas canisters if you are using a gas other than compressed air
• Special gloves for wielding a plasma cutter since the heat is higher than for a regular welder
• The plasma cutter itself

Final Thoughts

Plasma cutters need gas to operate. You can buy argon-hydrogen, nitrogen, or oxygen, but for most DIY uses, plain compressed air from your shop works best as long as it doesn’t have lots of dust or moisture.

The post Do Plasma Cutters Need Gas? appeared first on Beginner Welding Guide.

If you’re working with metal often, you’ve probably come across a plasma cutter. Plasma cutters are tools that have been around since the 1960s. They use plasma, or a gas heated to very high temperatures, to cut through powerful metals. Plasma cutters are used anywhere from factories to autobody shops because they cut through metal easily.

However, plasma cutters are used most often for thinner metal sheets such as aluminum. You may be wondering if you can use this tool to cut through thicker metals. The answer depends on the type of plasma cutter you are using, since handheld cutters are very different from massive computer-operated machines.

Here is your guide to finding the right plasma cutter for the thickness your project demands.

How Thick Can a Plasma Cutter Cut?

It is hard to answer this question because there are so many different types of plasma cutters. 

Smaller machines have less power and will only cut through thinner material. Handheld plasma cutters usually cut material with a maximum thickness of 1.5 inches (38 mm). This is good enough for most DIY uses since you work mostly with thinner metal for at-home use. However, this is not thick enough for industrial usage.

That is why factories and industrial workers invest in far more powerful industrial plasma cutters. These cutters are massive machines that are controlled by computers. They can cut through metal up to 6 inches (150 mm) thick. Most DIY welders won’t experience this power since these machines are too expensive for the average home welder. Still, you usually don’t need to cut this thick material for your backyard welding projects.

What Metals Can a Plasma Cutter Cut?

The thickness of the metal is not the only factor that affects how well the plasma cutter will work. The type of metal you are using also affects the cut’s quality. Plasma cutters do some of their best work with steel, providing a faster, thicker cut. 

However, these versatile machines work with many different metals. The quality of the cut will be different depending on the metal you are working with, and you may need to adjust your technique (and expectations) to get the best possible cut.

The list of metals you can use a plasma cutter with includes:

• Mild steel
• Stainless steel
• Steel alloys
• Aluminum
• Carbon steel
• Copper
• Brass
• Ferrous (iron-containing) metals
• Titanium

This is not an exhaustive list, and you can use plasma cutters with almost any metal as long as you adjust the settings right.

How Does a Plasma Cutter Work?

Plasma cutters seem like such intimidating tools, especially to beginning welders. That is why I also have a guide to using a plasma cutter. 

It is helpful to understand how these tools work to make using a plasma cutter less intimidating. Plasma cutters work by heating pressurized gas until it reaches a plasma state, which can cut through metal. 

Here is a step-by-step explanation of how these tools work and why they’re able to slice through metal so easily.

1. Plasma cutters have a full gas canister. Plasma cutters are powered by pressurized gas, usually oxygen, argon, or nitrogen.

2. The pressurized gas is forced through a narrow channel. The small opening increases the speed and pressure of the gas, which ultimately increases the temperature. It also concentrates the gas so you can create a directed plasma arc.

3. The gas is exposed to a negatively charged electrode in the plasma cutter. This electrode is very important because it causes a spark. Electrical energy converts to thermal energy, which heats the gas until it reaches the plasma state. Plus, electricity creates a circuit, which directs the plasma into the metal.

4. The charged gas heats until it enters a charged plasma state. The plasma is forced out from the nozzle at a high speed and temperature, melting the metal. The plasma is also charged thanks to the spark from the electrode. When it comes in contact with the metal, it creates a melted pile of slag. The plasma connects to the metal thanks to its charge, which binds to the charge in the metal to create a completed electrical circuit. 

Meanwhile, the rest of the gas that doesn’t turn into plasma flows through separate channels away from the electrode. This gas functions as a shielding gas, which blocks oxygen and moisture from entering the weld and damaging it. 

5. Turning off the plasma cutter breaks the circuit. When you power off the plasma cutter, the electrode is no longer charged, breaking the circuit and cooling the gas.

How to Use a Plasma Cutter to Cut Thick Metal

If you need to cut some thicker metal, here is the best way to get the most out of your plasma cutter. 

1. Make sure you are using the right plasma cutter. If you want to cut a piece of steel several inches thick, no amount of fiddling with the settings on your handheld plasma cutter will make it work.

2. Prepare your set-up and equipment. Working with plasma is dangerous, so you want to protect yourself. Make sure you have a welding helmet and special welder’s gloves. Plasma cutters are hotter than TIG or MIG machines, so you need gloves that can withstand higher temperatures.

3. Adjust the amperage. The higher the amperage, the more powerful the plasma arc will be and the deeper the cut will be. A good rule of thumb is that for every additional 1/10^th of an inch (or 3 mm) in thickness, increase the amperage by 10 amps.

4. Cut the metal. A good technique for plasma cutters is holding the tip at a 45-degree angle and dragging it toward you. Make sure sparks are traveling away from you.

Final Thoughts

Plasma cutters are excellent tools for cutting metal. Handheld cutters can cut metals up to 1.5 inches thick, while industrial machines go even thicker. 

The post How Thick Can a Plasma Cutter Cut? appeared first on Beginner Welding Guide.

You must follow some safety precautions to avoid eye or skin damage.

So how do plasma cutters get their heat, and how to deal with this incredibly high temperature? In this article, I’ll show you just that.

What Is Plasma?

Plasma is one of the four matter stages, and it’s the one responsible for giving the cutter its extreme heat. But how does that happen?

The temperature of matter affects the distance between its particles. For instance, the distance between the particles is much tighter in the solid than in the liquid or gas forms of matter.

Plasma, on the other hand, goes the extra mile. It breaks through the electrons, separating them from the molecules. This creates an electrical force that puts the molecules together as one, thus creating plasma.

The plasma cutter uses this scorching heat of the plasma to cut through different metals effectively. 

How to Handle the Heat?

Plasma cutters can get as hot as 40,000 or 45,000 °F (22,200 to 25,000 °C).

Let me give you an idea of how hot that is. The temperature on the surface of the sun is 9940 °F, which is almost a quarter of the plasma’s temperature!

Working with such extreme heat isn’t easy. Therefore, you need to follow some safety measures to avoid any hazards. Here’s a list of the hazards of using plasma cutters and the precautions you should follow:

Burns

When you use a plasma cutter, it generates sparks and heat to create the plasma arc. Therefore, you should ensure these sparks don’t contact your surroundings by having a spacious workplace. When the plasma arc cuts through metal, it drastically increases surface temperature. 

This also means that while using the cutter, everything around you will be extra hot, including the nozzle, the torch, and the workplace in general. So don’t touch anything or allow anybody to get close to your workplace before the temperature goes down.

Fire Hazard

With sparks flying around you, using a plasma cutter can be a fire hazard, so ensure you wear protective flame-resistant clothes during operation.

In addition, you should make sure that you don’t have any lighters or matches in your pockets, as this can cause them to explode or catch fire.

Eye Protection

You need eye protection while dealing with bright plasma. For this matter, you should wear dark safety glasses with side shields.

In fact, the cutter’s flame is so bright that you should avoid looking directly at it. This flame is capable of causing permanent eye damage.

Hand and Foot Protection

With such a high temperature, you should protect your hands and feet. For this matter, you can wear leather gloves or welding gloves to protect your hands. However, wearing gloves doesn’t mean that you’re perfectly safe. 

This intense heat of the plasma cutter’s flame can burn your skin even underneath the gloves. To avoid the risk of burns, don’t ever work with a plasma cutter bare feet.

Suspended Holder

Using plasma cutters isn’t an easy task. For instance, you shouldn’t leave your cutter on any surface as it can cut it accidentally.

Alternatively, you need to have a suspended container to keep the cutter. This avoids inflicting any damage on any surface that’s not intended to be cut.

Can You Modify the Temperature of a Plasma Cutter?

Fortunately, there’s a way to modify the temperature of your plasma cutter. All you need to do is adjust the temperature control on your plasma cutter.

Don’t worry about reduced effectiveness; plasma cutters are still effective even when not in full force. 

Advantages

Plasma cutters aren’t your only option. Some people opt for laser or water cutters to reach almost the same results. Following is a short list of the advantages and disadvantages of using plasma cutters:

There are three main advantages to plasma cutters. They’re cheaper, faster, and handier than other types of cutters.

For starters, when it comes to price, plasma cutters win. They’re relatively cheaper than other options in the market. This makes them a better option in many cases.

In addition, plasma cutters are portable, making them more convenient to use. Another major advantage is that plasma cutters are much faster than other cutters.

Disadvantages

One of the significant downfalls of plasma cutters is that they leave unfinished metal corners as they cut through.

You won’t get this residue if you use laser or water cutters. Other cutters give cleaner cuts that need almost no finishing work.

Getting a plasma cutter may be cheap, but the cost of using it is significantly higher than other cutters.

This is because your cutter requires a great deal of electricity to generate plasma. To mitigate this problem, you should extinguish the plasma flame as soon as you finish.

What Metals Can You Cut with a Plasma Cutter?

Plasma cutters can work with pretty much any metal. However, it must be conductive. The most common types of metals that plasma cutters can cut through include:

• Copper
• Mild steel
• Titanium
• Aluminum
• Stainless Steel
• Cast iron
• Inconel
• Monel
• Brass

Handheld plasma cutters can cut through mild steel up to 1.5 inches thick, while industrial models can go much thicker.

Conclusion

Plasma cutters get extremely hot, with a temperature that reaches between 40,000 and 45,000 °F. They can cut through any conductive metal, making them handy tools despite their hazards.

Before using a plasma cutter, ensure that you follow the safety measures to avoid hazards such as burns and even fires.

The post How Hot is a Plasma Cutter? Temperature Guide appeared first on Beginner Welding Guide.

When you first get into metalworking it can be pretty overwhelming. There are tons of principles and practices to learn for you to actually become good at metalworking… There are a few machines and tools you will need to master including Plasma Cutter.

It is a great tool to have. Especially if your building or running a fabrication business. It is portable, easy to use and can really make you some quick money.

I started using a plasma cutter several years ago, and I wish I learned about them even sooner. Before my new favorite tool came along, I would use an angle grinder and a bandsaw to make all my cuts. But now, my plasma cutter takes on all that heavy work with ease.

I’ll share my experiences and know-how that I have learned along the way. Don’t worry, even if you’ve never heard of Plasma Cutter and how to use it, I promise you will have a solid working knowledge when we are finished.

So, let’s jump in and explore the plasma cutter, how it works and the different types available on the market.

What is a Plasma Cutter?

Now, to really understand a plasma cutter it’s important to talk about the science behind it. You’ll not only have a deeper knowledge of the machine, but you’ll have a better idea of how to troubleshoot problems if and when they come up.

How Does a Plasma Cutter Work

“So what’s the deal – I just buy a plasma cutter, hook up the gas and electricity and I’m good to go… right?“ Well, not exactly.

Plasma cutters work off of different types of gas, they could use compressed air (like your shop compressor), argon or oxygen. In this article, we will stick to hand-held plasma cutters so the majority of these machines will run off of compressed air.

Now, here is the cool part.

We all know about ice, steam and liquid water right? Yes, we are stepping back to our 6th-grade science class for a second. The ice, steam, and water represent the different states of matter we are all familiar with: Solid, liquid and gas.

But hold on a minute: there is the 4th state of matter that we rarely discuss- Plasma.

How does plamsa differ from a regular gas?

One way plasma differs from a regular gas is that it has an equal number of both positively and negatively charged ions.

Whenever high heat is applied to the gas, thus turning it into plasma, it is endowed with a rather unique capability. When plasma is directed at high speed toward a piece of metal, the electrons in the plasma collide with the base metal. Consequently, the metal is literally melted and blown away in the form of a cut.

Now that you know a little about how a plasma cutter actually works, let’s talk about the setup and tools you’ll need.

Setting Up a Plasma Cutter

The plasma cutter itself is a pretty straightforward machine. With a basic handheld model, you have your torch and your electric and gas inputs. It’s important to know that a plasma cutter needs dry air supply.

• Most machines come with a filter to dry and remove any impurities from the air feed. But some value machines do not. So keep that in mind. A good compressor for the shop would be this one.
• For the hobbyist, a plasma cutter that can run on either 110v or  220v is a nice choice. Since 110v is available just about everywhere, this type of machine is highly portable. However, the metal thickness you can cut using 110v is limited to the much thinner stuff. Take a look at the plasma cutter the owner of this site uses, here.
• Once you have your air setup and your machine is plugged in, you are ready to go. You simply mark your metal and start to cut. Keep in mind, most machines need 220v for metal thicker than ⅜” inch and above.

NOTE: The biggest thing to keep in mind for the new user is this, travel speed. A good rule of thumb is the thicker your metal, the slower your travel speed needs to be. If you move too fast you'll fail to achieve a thorough cut.

Consumables

Just like welding, there are consumables you will need to replace from time to time when using a plasma cutter. The main item that will need replacing every so often is the tip.

NOTE: Some brands are designed so that you must purchase their tips. And others come with generically designed tips which are available at a much cheaper price. This is just something to keep in mind when deciding on which cutter to purchase.

Where To Use a Plasma Cutter?

So far we covered a bit of the science behind the plasma cutter, the machine itself and the setup. Now let’s shift gears and talk about major uses for a plasma cutter and where to best use a plasma cutter.

You can find plasma cutters in the field and in the shop. Sometimes they are dedicated shop machines and sometimes you can use a portable machine in the shop and in the field as previously mentioned.

It all really depends on your needs and the projects you want to work on. But ideally, you will want to have a dedicated shop and a separate field machine.

Portable plasma cutters for Field Use

There are many portable plasma cutters on the market to choose from. They range in price from the inexpensive value brands to high-end models. Most of the machines are pretty solid performers. Just be wary of the bottom of the barrel machines. You will probably end up with something less than useful.

Yeswelder is becoming more and more popular in the welding space It offers great value for money and you should definitely give them a look.

For field use, you’ll want a machine with 15′ or 20’leads. This is so you can easily reach your work and still be able to hook up your air and electricity.

TIP: You can also run a plasma cutter, or welder for that matter, off of a generator if there is no 110v power available. I’ve done this several times and it is great to know that this is an option. With a generator, you are truly 100% portable.

Where do you typically Use Portable Plasma Cutter?

Typical use will vary and are going to be based on the projects you are doing. Therefore, let me give you some ideas about the projects I’ve used my field plasma cutter to complete.

Apartment renovations

We had a project where an older building was being converted from rental apartments into condos. The designers wanted all the trash chutes and HVAC ductwork removed for a new high-efficiency system. To save time we had about 12 plasma cutters going at once (on different floors) to cut out and remove all the duct work.

Art Installations

Artists can be a fickle bunch, so sometimes it best to do finishing work in the field. We once had a 35’ steel figure that had to be secured into the ground and to the adjacent building.

Once the artist liked the “look” of the statue’s support, we had to fabricate steel anchors to fit curved metal. So, we traced cardboard along the figure to get an exact fit. We then traced our cardboard over the steel and cut the anchors with the plasma cutter.

Maintenance

Sometimes we come across a machine or a structure that needs a small repair. A plasma cutter can efficiently cut an odd shape or small piece of metal without having to go back to the shop. It saves time and completes a repair quickly.

Using Plasma Cutter inside Shop

Now, shop use is a bit of a different story with plasma cutters. They can be used with a CNC machine and the results can be amazing. You can take a raw sheet of steel and transform it into some amazingly designed work of art.

More than just making beautiful pieces, these designs can be repeated over and over. This allows your shop to take on big orders for larger clients.

Some examples I’ve seen :

• Design and produce 79 window guards for a small apartment building
• Produce 125 metal pumpkins for a small town Halloween festival
• Design a metal exit door for a museum (with stain glass to be added)

This is just the tip of the iceberg when it comes to shop use with a CNC table. But the main idea is that you can produce accurate cuts over and over again. This can be a big deal if you are looking to break into production work or have a job where you require a lot of the same parts.

Attachments and accessories for a Plasma Cutter

I would like to cover some of the attachments and other items for plasma cutters. Just in case you may not want to go the CNC route. You may have a fabrication shop or are thinking about doing some of that kind of work.

In that case, some great attachments and accessories to have would be the following

Plasma cutting table

Here is a good one from Eastwood. It’s very handy to have for two main reasons:

1. you don’t want to cut on the floor and
2. if you secure the metal to your welding table, the part you cut will usually fall to the floor.

This table allows you to make secure cuts and supports your entire workpiece.

Cutting guide

Here is another good one from Eastwood.  Sometimes you need to make a curved cut. Especially, if you’re working on car body panels or artwork. This guide will allow you to run your torch along the edge for an accurate cut.

Circle kit

Let’s say you need to fabricate a steel bar, and to anchor it in place you’ll need to cut 73 through holes so you can bolt this bar in place. How can you do that easily? With a circle attachment. Or let’s say you need to cut circular disks for an art installation – well, this attachment will come in handy for you.

You can use a plasma cutter effectively in the field and in the shop. Depending on the project you may need some attachments to produce high-quality work quickly and effectively.

Most of the time you can purchase the attachments and tools as you go, so over time, you have a good selection of attachments to make jobs much easier.

Difference Between Plasma Cutters vs Multi-process machines

The major difference between a plasma cutter and a multi-process machine is this: the plasma cutter will have one function, cutting. The multi-process machine will have several functions, usually stick welding and TIG welding in addition to plasma cutting.

Should you buy a multi-process machine or Plasma Cutter?

There is no hard and fast rule to answer this question, but it comes up a lot so I’ll give you my best answer.

• If you are a DIY’er and like to weld on the weekends, then a good MP machine will suit you well. You can hook up to 110v (home power) and cut ⅜” steel without a problem. Then you can easily set your machine weld.
• An MP machine is a good investment and owning one will save you space rather than owning separate welders and a plasma cutter.
• If you are a small business or general contractor then it pays to have a dedicated plasma cutter. You’ll be more efficient at jobs and the savings in labor cost will pay for the machine in no time – including any special attachments needed.

How to use Plasma Cutter in Detail?

Every plasma cutter is going to operate a bit differently. Consequently, it’s always best to consult your owners manual before starting. Some like the Lincoln plasma cutters will have built-in air and safety guards. While others will need shop air and have limited safety guards.

Below are a few general points that we will cover in this article concerning how to effectively use a plasma cutter. We have broken them down into bite-sized pieces.

Step 1. Getting the Machine Ready

When you’re ready to use your plasma cutter let’s make sure everything is hooked up and ready to go.

• If your machine needs external air, then hook up the line now. If the machine compresses it’s own air, make sure the unit is hooked up to electricity, the pressure gauge is active and the air is building up.
• Your machine will have a specific air pressure for optimal cutting, be sure to reference the manual. When you begin to cut the air pressure will drop. This is normal and to be expected. When you release the trigger and stop your cut the pressure will build back to whatever PSI you selected and the gauge will show your current PSI.

Step 2. Adjustments

Now that your machine has power and the air is flowing, you’ll need to make some adjustments.

• Check your Amperage. You’ll need to set your amps to accommodate your cutting material. The rule here is of course, the thicker the material the higher the amps. Many machines will have the standard 50 amps. And those will cut everything ½” thick and less. Lower amp machines will necessarily be reduced to cutting thinner materials.
• The Torch. Since you’re cutting with very hot compressed air most guns have two safety features built in.
  • The first being non-operation: the machine will not work if the torch is assembled and missing a piece.
  • The second safety is the trigger guard. Since the plasma cutter will cut anything that conducts electric you want to make sure you’re aligned with your workpiece and ready to go. So once you have the torch-lined up you’ll want to lift your guard then depress the trigger to cut.

Safety

We’ve just covered the current adjustment of the plasma cutter. But let’s talk about you for a second. Cutting with plasma is messy. Sparks and dross can fly everywhere. Especially if your travel speed is off. So, in order to be safe you’ll need:

• Good eye protection. Welding requires a hood because sparks fly toward you and the light is much brighter when compared to plasma cutting. We recommend that you use shaded cutting goggles or a welding helmet with an adjustable shade.
• A flame resistant jacket is also essential.

Operations

Ok, you have your plasma cutter machine ready and powered up. The amps are adjusted to the material your cutting and both you and the machine are safe. Let’s talk operations.

If you’re using a cutting guide you will want to have that lined up for a straight cut. Have your magnetic guard set up if it’s a curved line.

• Take your torch and line it up 90 degrees to your workpiece. You’ll then depress the trigger and start to move it along the workpiece. You’re actively making a cut at this point. Notice your travel speed.
• Travel speed is important to note, and it’s easy to determine if you’re moving too fast or too slow. Here’s how :
  • Travel speed too fast: sparks and dross will fly upwards towards you, the operator. If that is happening then slow down your speed right away
  • Travel too slow: You might notice an uneven cut. If you’re moving too slow you might give the torch room to wander left or right, resulting in an uneven cut if you’re not using a guide.
  • Travel speed is just right: all the sparks and dross will be falling to the floor as you are making a through cut.
• Finishing the cut: Strive to keep the angle the torch a true 90 degrees. This will ensure the cut is clean. If there are a few places that were not cut all the trough you’ll need to grab a hammer and give the piece a little tap so it separates completely.

Conclusion

In this article, we covered the science behind a plasma cutter, the different types of cutters available, attachments and accessories you’ll want to consider and the major uses for a plasma cutter.

Plasma cutters are versatile and easy to use machines that the DIY’er and the professional alike can use. There are many available in today’s market, and you can get a good MP machine, a small consumables kit and a shop compressor to get you started.

If you have welding experience under your belt and you want to take on bigger and more complex projects a plasma cutter is a great investment.

Reading Guide

• What do I need to start welding as beginner?
• Plasma cutter or oxy/acetylene torch?
• 8 Tips for MIG Welding Beginners
• Should I Buy or Build a Welding Cart
• Best Welding Machine for Beginners
• Best Footwear for Welding
• How to demagnetize metal for welding?

The post How to Use a Plasma Cutter for Beginners appeared first on Beginner Welding Guide.

Using fire to perform work carries risks. However, with a little precaution and knowledge of the process, cutting with a torch can be done safely.

The cutting torch and its parts

Oxygen and acetylene gases come together and are mixed in the handle. The volumes for each are fine-tuned with adjustment valves on the handle. The proper flame setting needs to be achieved before cutting steel. The fuel gas is acetylene. Oxygen is added to increase the heat to as much as 6300 degrees Fahrenheit. Each gas is contained in its own, separate cylinder.

Regulators are connected to control the high pressures in each bottle and reduce or regulate the pressures to a usable level. On top of the handle where the gases are mixed, is where the cutting torch assembly is attached. A third valve is part of the cutting attachment. This additional valve is the second valve in line controlling the flow of oxygen to the cutting tip. The first valve in line (the one on the handle) is left fully open.

A lever on the back of the cutting assembly supplies full oxygen pressure to the tip at will. This pressure and flow is completely unrestricted and regulated by whatever the regulator on the oxygen bottle is set to.

To summarize, the parts of the cutting torch consist of:

• Oxygen and acetylene bottles
• Two regulators, one for each bottle
• Two hoses, one leading from each regulator and each ending at the handle.
• The handle
• A cutting torch assembly with changeable tips

How to use a welding torch?

Welders use cutting torches to cut through metal. It’s a critical step in the welding process; if it’s not done properly, the weld can be ruined. Here are the steps to take before you start cutting:

Things to do before you cut with a Cutting Torch

Here are essential steps to take before you start cutting:

• Remove all flammable materials well away from the cutting area
• Flammable materials include dry materials such as paper, cardboard, sawdust and dry grass
• Station a fire extinguisher nearby
• Wear goggles and heavy leather gloves
• Wear flame-retardant clothing or well-fitting 100% cotton clothing with no frayed edges
• Good leather boots are recommended
• NEVER wear nylon or any synthetic or synthetic blend material around welding or cutting. It can melt to your skin.
• Have your metal marked with soapstone precisely where you want to cut. Soapstone will allow you to see the marked line just ahead of the torch tip.
• Only use a striker made specifically for igniting a cutting torch.

Setting the regulators

The regulators are specific to either the oxygen or acetylene bottle. They cannot be accidentally switched because the oxygen bottle has a male right-handed thread connection and the acetylene bottle has a female left-handed thread connection.

Once the regulators are connected to the bottles and the hoses are properly connected to the regulators and torch handle, its time to properly set them. Note: The acetylene hose will be red with left-handed threads and the oxygen hose will be green with righthanded threads. Be careful not to cross-thread the soft brass fittings and do not overtighten. Just snug the fittings up to the point they do not leak.

With the control knobs on the torch handle closed and the adjustment knobs on the regulators turned all the way down to the lowest setting, slowly crack open one bottle at a time. Once the pressure has equalized between the bottle and the high-pressure side of the regulator, open the bottles up fully.

Acetylene Regulator

Slowly open the knob on the acetylene pressure regulator until the low-pressure side gauge reads between 6 and 8 psi. Slightly open the acetylene valve on the torch to allow a small flow of gas to escape and see if the pressure setting stays where you set it. If not, continue to adjust until properly set. Do not allow the low side pressure on the acetylene regulator to ever exceed 15 psi.

Note: A full bottle of acetylene should read +/- 225 psi on the high-pressure side of the regulator. 

Oxygen Regulator

Slowly open the knob on the oxygen pressure regulator until the low-pressure side gauge reads between 30-40 psi. Slightly open the oxygen valves on the torch to allow a small flow of oxygen to escape and verify the pressure setting stays where you left it. Again, if not, continue to adjust until properly set.

Note: A full bottle of oxygen should read +/- 2250 psi on the high-pressure side of the regulator. 

Lighting the torch

With the bottle valves wide open and regulators set, let’s light the torch. Ensure the torch tip is pointed away from you and not towards anything flammable.

1. Slightly crack open the acetylene valve and immediately ignite the gas, leaving the tip with the striker. Adjust the acetylene valve until the yellow flame is approximately 10-12 inches in length.
2. Open the oxygen valve on the bottom of the handle fully, then slightly open the second oxygen valve until the flame turns from yellow to blue.
3. Continue adding oxygen until the inner, light blue flame constricts toward the tip.
4. Once the light blue flame is pulled down to the crown-shaped cone, press the oxygen lever on the back of the cutting torch. The light blue flame should not extend away from the tip. If it does, slightly reduce the oxygen volume by pinching back the valve all while the lever is still depressed.

Making the cut

1. Bring the tip down to the point on the metal where you want to start cutting.
2. Keep the end of the light blue flame at the metal’s surface until bright red and near the melting point.
3. Press the cutting lever and if the base metal is hot enough the additional oxygen will cause a reaction and the metal will begin blowing away from the tip. If the metal has not reached a high enough temperature there will be no reaction.
4. With a smooth, steady hand, direct the tip along the marked path at a speed that allows the complete blow-through of the molten metal until the cut is complete.

What happens during the cutting process?

Once the cutting torch head is attached to the oxy/acetylene handle, it becomes a powerful instrument for cutting metals. The focused flame from the end of the torch tip pre-heats the metal until cherry red. A blast of pressurized oxygen then increases the heat substantially and blows the molten metal directly away from the tip. The initial torch flame only starts the process. The blast of oxygen causing the formation of iron oxide, literally causing the metal to burn, creates the extra heat necessary to cut through the metal. The torch is then moved along a determined path until the cut is finished.

The molten metal blown from the piece being cut is called slag. When the oxy/fuel mixture is adjusted correctly, a clean cut can be made without leaving very much slag attached to the base metal.

Read More

• Plasma Cutter or Oxy/Acetylene Torch?
• How to Use a Plasma Cutter
• How to select Welding Amperage?
• Welding machines for Beginners
• Which is Best Footwear for Welding?
• Best Welding Helmets

The post How to Use a Cutting Torch for Beginners appeared first on Beginner Welding Guide.

If you are bootstrapping your new venture into welding, you may wonder which cutting system is best to start with.

There are other ways to cut steel without a plasma cutter or oxy/fuel torch. These include chop saws, hacksaws, angle grinders and pneumatically driven cut-off wheels.

Which of these tools ends up being the most practical depending on the thickness of the metal being cut and how much of it there is. You start hitting the limits of the pneumatic tools very quickly if your projects are of any size.

They have their place and can do some things very well. But, they are very limited in practicality. While the angle grinder with a cutoff wheel is just a larger version of the pneumatic tool, they also have limitations.

Both types can cut straight lines but neither are very good at cutting short radius curves.

On the other hand, chop saws can cut thicker steel much faster. They are good at cutting angles but can only make straight cuts. And a hacksaw will be good for only cutting the smallest of items.

An artist making small pieces of art might get by with just a hacksaw. But even then, they are severely limiting themselves if that is the only available tool.

What is a Plasma Cutter?

The plasma cutter uses electricity and gas under high pressure to cut through materials. As you might guess, the material being cut must be able to conduct electricity.

Thus limiting the materials that can be cut, to metals. Many metals can be cut but the most typical are steel, stainless steel, aluminum, brass, and copper.

The gas used varies depending on the metal being cut. For cutting steel, compressed gas, or air is typically supplied by a simple shop air compressor.

The actual cutting process entails the creation of an electrical pathway of superheated, electrically ionized gas, or plasma, originating from the torch and jetting through the metal to be cut.

The electricity completes its circuit back to the plasma cutter through the grounding clamp attached to the workpiece. The compressed air is blown through the focused nozzle in conjunction with the electrical arc is what creates the plasma and also pushes the molten metal away.

The electrical arc ionizing parts of the gas is what actually forms the plasma.

Check out this video from Hobart about plasma cutting:

What type of work does the plasma cutter perform best?

Plasma cutters produce a very thin stream of superhot plasma to cut with. This means the surrounding metal near the cut is not exposed to much heat during the cutting process.

This works out well for auto body work in addition to all work done on thinner metals which might warp if too much heat is introduced during the cutting process.

The narrow cut is very precise, leaving a smooth edge. This lends itself for the plasma torch to easily be attached to a computerized axial cutting table with which very intricate cuts can be made quickly.

Also known as a CNC table, these devices can cut multiple pieces that are identical, wasting very little of the original sheet. Or, they can be used to cut one-off pieces of very intricate, highly detailed work designed in a computer program.

What else do I need before I can start using a plasma cutter?

Assuming you will be starting out with one of the smaller, entry-level machines, you will need a 230v outlet and an air compressor with sufficient output to accommodate the needs of your particular plasma torch.

You can purchase a plasma cutter with a built-in compressor that will run on 120v but I am wary of them. When you decide you need a Plasma cutter, save for a more powerful unit.

You will need leather gloves, an apron or a jacket for protection from the heat and sparks.

I personally prefer a welding jacket like this one by Lincoln Electric. It is designed especially for high-amperage welding and out-of-position welding. It has a two-part armpit design that actually allows you to move your arms which is much more comfortable than the old-fashioned leather jackets.

Green-tinted filters for eye protection are recommended. Longevity Global Inc. created the chart below for guidance:

For welding helmets with adjustable shading that can be used with a plasma torch, go here!

What is an Oxy/Acetylene Torch?

• Gas service: Acetylene, Oxygen regulators: ess3-125-540, fuel Gas regulator: ess3-15-510
• Cutting tip: 0-3-101
• Heating nozzle: 4-mfa-1
• Welding nozzle: (w-1) 0

Check Price On Amazon

Invented in 1903 by two Frenchmen, oxy/fuel welding began as a means to fuse metal by combining pure oxygen and a fuel gas such as acetylene. Pure oxygen is used to increase the heat generated from the flame.

The acetylene/oxygen mixture burns at over 6,300 degrees Fahrenheit.

Forged welding is the second oldest welding process next to oxy/fuel welding. Since the advent of arc welding, very little industrial work is still performed with the oxy/fuel process. Artisans still use the method for creating artwork.

When the cutting torch head is attached to the oxy/acetylene handle, it becomes a powerful instrument for cutting metals. The focused flame from the end of the torch tip pre-heats the metal until cherry red.

A blast of pressurized oxygen then increases the heat substantially and blows the molten metal directly away from the tip. The initial torch flame only starts the process.

The blast of oxygen causing the formation of iron oxide, literally causing the metal to burn, creates the extra heat necessary to cut through the metal. The torch is then moved along a determined path until the cut is finished.

The molten metal blown from the piece being cut is called slag. When the oxy/fuel mixture is adjusted correctly, a clean cut can be made without leaving very much slag attached to the base metal.

One key to a quality cut is starting with a clean tip on the torch. This includes the nozzles. A small tip cleaning kit with an assortment of cleaning wire sizes is a must.

What else do I need before using an oxy/acetylene torch?

Besides the handle and cutting head attachment, you will need:

• Gas hoses, one red and one green
• Two regulators, one for the oxygen bottle and one for the acetylene bottle
• A bottle of oxygen
• A bottle of acetylene
• A striker for igniting the flame
• Tinted goggles, glasses or hood for eye protection
• Gloves, apron or jacket to protect from the molten slag
• A secure cart or area to store the bottles
• A safe place to work
• A tip cleaner

Fortunately, most of the above can be purchased in a package. First, determine the best size torch for your immediate and future needs and choose the package accordingly.

The Victor Medium Duty Torch kit is a great torch that will handle almost everything the hobby shop welder will ever encounter.

Your local welding supply store will gladly rent oxygen and acetylene bottles to you.

So which one do I recommend?

The choice is easy. For my purposes, and I believe most of yours, the oxy/fuel torch system is the way to go for your first buy. Like me, you may want to add a plasma cutter at some point in the future as your work progresses.

Purchasing the above kit and renting bottles will be cheaper initially than getting set up with a plasma cutter. Plus, the additional things you can do with an oxy/fuel torch outweigh the limited abilities of a plasma cutter.

For instance:

• You can’t warm up a rusty bolt or nut to aid in its extraction with a plasma cutter.
• One cant heat metal to the point where it can be bent or reshaped with a plasma cutter.
• You can’t burn debris and paint off metal with a plasma cutter

More Information

• How to Use a Plasma Cutter?
• Beginner welding Projects
• Best Pipeline Welders
• The Best Welders for Beginners
• How to use a welding torch?

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