What is plasma cutting/How Does A Plasma Cutter Work?

Plasma cutting is a process used to cut steel and other metals with various thicknesses with compressed air. Generally known as the Oxy Acetylene killer, the plasma cutting

Plasma Cutter History

Process is much cleaner, faster, and a more efficient way to cut metal. The plasma cutting process begins compressed air blown out of the nozzle (a part of the plasma torch) at extremely high speeds, while at the same time an electrical arc is formed through the nozzle via High Frequency or Pilot Arc starting methods through the nozzle to the surface being cut causing the gas to turn to plasma.

By adding electricity through an electrode (hafnium), the gas becomes imbalanced and conducts electricity. The more electrical energy added, the hotter the plasma arc becomes

Plasma Cutters have been around for over 50 years. Plasma Cutters were a major part of World War II era. During the war, there was a demand for a more efficient and speedier way to cut and mold metal for aircraft maintenance and production.

After the war, the plasma cutter process was so effective it was widely accepted by manufacturing and production companies as it considered the best way to cut metal. Fabricators realized the cutting quality and the effectiveness of the cut was a great addition to the manufacturing world.

In recent years with the development of transformer unit and plasma cutter inverter technology, plasma cutters have become more affordable and available to small fabrication shops, auto body shops, manufacturing plants, Welding professionals, welding hobbyists, and garage shop owners.

Longevity has been a leading manufacturer of affordable plasma cutting and welding equipment allowing even more individuals the opportunity to use, feel, and own a plasma cutter due to the low cost pricing.

Today, Longevity® produces quality and affordable plasma cutters for all individuals and a must have tool in your plant, shop or garage.

Plasma Cutting vs OxyFuel (Oxy-Acetylene)

Since plasma cutting is a fairly new technology compared to OxyFuel cutting, there has been a great debate on which process is more affective, which to purchase, and whether upgrading to a plasma cutter is worth the money. To answer some of the debated topics, Longevity will explain

the difference of the two processes and point out some key facts to help you make an informed decision on whether or not a plasma cutter is a good investment for you. There are various factors that you must considering before investing in a tool that will cut metal in guidelines with your needs. Some of these factors are the thickness of the cut, location of work, type of metal, power resources, and operating costs just to name a few.

How does each process work?

Plasma Arc Cutter:

The plasma cutter process works when gas (mainly compressed air) blowing through at high rates combined with electricity forming an arc that is extremely hot causing metal to melt away while blowing off the slag.

Plasma Cutter Basics:

With a power source 110/220v, a torch, consumables, and compressed air, you are able to use a Longevity Plasma Cutter virtually anywhere and anytime.

Oxy Fuel:

Oxycetelene also known as oxy fuel cutting works by preheating metal to igniting temperature with high power oxygen jet being directed at the metal creating a chemical reaction between the oxygen and metal forming an iron oxide, which is better known as slag.

The high powered oxygen jet then removes the slag from the kerf. The cutting quality, preheating time, and the thickness can all be influenced by the type of gas being used. Oxyfuel cutting is used for ferrous (iron-containing), mild and low alloy steels with thicknesses up to 2 feet or 24 inches.

OxyFuel Basics.

With a fuel tank, oxygen tank, and a torch, you can cut steel anywhere - except for nonferrous metals such as aluminum and stainless steel. Oxyfuel cutting allows to cut extremely thick metals with ease, and a variety of torch options allow users to braze, solder, fusion weld, gouge, preheat, and bend metals as needed. The process requires a lot more work for cleanup than Plasma Cutting.

Longevity® is providing an excellent chart that clearly shows each process and the capabilities of each method:

Plasma Arc Cutting Oxy/Fuel Cutting 

 

 

Plasma Arc Cutting

Oxy/Fuel Cutting

Metals

Plasma cuts any electrically-conductive metal (steel, aluminum, copper, stainless steel, etc.) from very thin (<3/8 in.) up to 2in.

Oxy/fuel cuts ferrous (iron-containing) steels up to 24 in. thick. Metals such as aluminum and stainless steel cannot be cut with Oxy/fuel due to the formation of an oxide that prevents oxidation from fully occurring.

Industries

Common in metal fabrication, construction, agricultural, maintenance, automotive repair, metal art, sculpting, home, hobby and DIY applications.

Agricultural, fabrication, construction, maintenance repair, mining, automotive, hobbyists, DIY applications

Preheating

Not required

Required

Productivity

Plasma cutting works exceptionally well on thinner materials (<1/2 in.), depending on the output of the power source. It can also cut stacked material and works well on expanded metals. Prep time is minimal with no preheating requirements. Produces a small and precise kerf (cut) width. Features a small heat-affected zone that prevents warping and damage. Cleanup is rarely needed as dross is cleanly blown away.

Oxy/fuel is capable of efficiently cutting metals up to 24 in. thick. It is not dependent on a primary power source. Fuel gas and nozzle design options enhance performance.

Portability

Portability varies based on technology, size of power source and size of air tanks (if not using a built-in air compressor). Many units can work efficiently in the field off of engine-driven generators and a variety of primary power sources thanks to primary power management technologies offered in some plasma cutters.

Highly portable and is not dependent on a primary power source – capable of cutting anywhere with gas tanks and torches.

Versatility

Stack cutting, beveling, shape cutting, gouging and piercing of metals is possible with plasma cutters.

With a combination torch, oxy/fuel systems can be used for heating, brazing, soldering, welding,gouging, riser cutting and bending metals.

Safety Concerns (Operated properly, each tool is safe and effective. Improper use can lead to the following problems.

Electrocution, fires started by sparks, arc flash to the eyes, cutting in and around combustible materials, damage to protective clothing, skin and tissue if used improperly. Always wear appropriate clothing.

Flashbacks, fires started by sparks, cutting in and around combustible materials, damage to protective clothing, skin and tissue if used improperly. Always wear appropriate clothing.

 

Arguments for a Longevity Plasma Cutters and the Plasma Cutting Process:

Longevity Plasma Cutters allow for the metalworkers to cut metals more quickly without preheating or much cleaning up to 2 inches with a 220v single phase plug rated at 100amps. The plasma cutter process is the newest generation cutting method because it is portable, can be used anywhere, and produces quicker and cleaner looking cuts when compared to Oxy Fuel cutting.

Plasma cutters are also popularly used with CNC tables (automated cutting machines) because of their precise cuts. In addition, Plasma Cutters can cut any type of metal

Arguments for OxyCetelene (OxyFuel) Cutting:

Oxyfuel cutting is a time-honored cutting tradition. With certain metals Oxyfuel takes less time to cut various thicknesses in comparison to a plasma cutter. Unlike plasma cutters, oxyfuel does not have ratings of rated cutting thicknesses. The thickness of the cut depends on the gas used and the tip at the end of the oxyfuel torch – making oxyfuel more universal for various thicknesses of cutting.

Oxy/fuel Fuel Gas Basics

Acetylene

Produces the highest flame temperature of all common fuel gases. The hotter the flame – the faster piercing occurs. The higher calorific value of the inner flame vs. that of other gases makes acetylene the fastest cutting gas with the least amount of distortion and the narrowest heat affected zone – which is why it is arguably the most popular gas. Also features the lowest oxygen-to-gas ratio of (1.2:1).

Propane

Lower flame temperature than Acetylene but has a greater total heat of combustion, making it equally fast at cutting. But with most of the heat being generated in the secondary flame, the flame is less focused, causing slower piercing times. Suffers from a relatively high oxygen-to-fuel gas ratio (4.3:1) required to meet maximum flame temperature.

Methylacetylene-propadiene (MAPP)

Slower piercing and cutting times than Acetylene due to lower flame temperature, larger distributed heat source and gas flows – but can be used at higher pressures than Acetylene (i.e., less combustible). Oxygen-to-gas fuel ratio is (2:5:1).

Propylene

Similar in temperature to MAPP, hotter than propane, cooler than acetylene but requires a high oxygen-to-fuel gas ratio (3.7:1).

Natural Gas

Slowest gas for piercing, with lowest flame temperature and lowest total heat value.

Plasma vs OxyFuel Pricing:

Before Longevity® introduced affordable plasma cutters, plasma cutting was generally more expensive than Oxy Fuel cutting. With Longevity providing quality plasma cutters at affordable prices, you are able to purchase a high amp plasma cutter than will cut thick metals quicker, more efficiently, and more with fewer cleaning required at a lower operating cost. Longevity® releasing affordable plasma cutters has heavily favored the outcome pushing more metalworkers toward trying the newest generation cutting method: plasma cutting.

Portability:

Prior to Longevity® introducing their line of inverter plasma cutters, most plasma cutters were transformer based machines, which were not portable at all. Longevity® inverter plasma cutters have enabled metalworkers to cut ¾” from a 25 pound portable machine. With such little weight and such power, Longevity® has enables plasma cutting to be the most portable and effective cutting method to date.

Safety:

Both plasma cutting and oxy fuel cutting methods are can be hazardous if not used properly and with full safety precautions in affect. Both methods can cause fires and have unique dangers. In order to safely use each cutting method, one must follow the safety guidelines of each method – choosing which is safer is impossible considering you are using powerful cutting processes. If we had to choose one or the other, we would state plasma cutting is safer because of the single fact that there is not an open flame from the torch.

Conclusion:

Plasma cutting is the latest and greatest method of cutting metal because of the portability, the cutting power of the machine, and the current cost to startup with Longevity® making affordable plasma cutters for everyone and anyone. Longevity® plasma cutters start at $549.99 with free shipping and a 1 year warranty for a 40amp machine capable of cutting ½” clean. That is an unbeatable deal!