What Is Hex Chrome And Does Plasma Cutting Produce It?

Obviously, when it comes to welding, safety is of the utmost importance. From following best practices to taking extra precautionary measures, it is imperative to follow a “safety first” mentality to protect yourself and those around you. Since hex chrome can pose significant risk to welders, it is necessary to know what hex chrome is and how to reduce exposure to it.

What is Hex Chrome?

Hexavalent Chromium, also known as “Hex Chrome,” or Chromium 6, or Chromium (VI), is a heavy metal that is known to be a potent carcinogen when inhaled. It can occur naturally, but various industrial processes, especially welding, generate these fumes.

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Plasma Cutter Uses: 8 Reasons to Go Plasma

While there are a lot of ways to cut metal, some methods are more effective than others. Plasma cutter uses in particular range in versatility from metal fabrication jobs to decorative purposes. Because of its high utility, plasma is the ideal cutting choice for many projects. So, here’s why you should be using a plasma cutter.

1. Plasma Cutters Have a Variety of Uses & Can Cut Any Type of Metal.

Steel? Check. Aluminum? Check. Stainless? Also check. Your plasma cutter isn’t a picky eater. You can feed it almost any type of metal or alloy. Since it uses an electric arc to cut all types of conductive metal, it is a productive way to get projects done. Although the cut quality will vary (especially depending on the gases used), your machine will eat it.

2. Plasma Cutting is Fast

Next on our list of plasma cutter uses is its ability to save you time on your projects. You can use a plasma cutter when you need to finish a project quickly. With cut speeds exceeding 100 inches per minute, plasma cutting is very fast compared to other methods. The speed will decrease with material thickness, of course, but for most everyday materials, plasma cutting offers considerable time savings.

3. You Won’t Need to Warm-Up Your Plasma Cutter

Plasma arcs can reach temperatures of up to 25,000 degrees Celsius. That’s almost five times hotter than the sun. That mind-boggling temperature is reached in milliseconds and will liquify metal instantly with no preheating. That means no waiting and no wasted energy.

4. Plasma Cutters Can Cut Almost Any Form of Material

If you wanted to cut various forms of metal (plate, tube, angle, beam, grating), you would need multiple different types of saws or shears. A plasma cutter can do it all. Some premium models even offer a continuous pilot arc mode that allows for cutting of expanded metal or grating with no loss of cut.

5. Plasma is Versatile

As mentioned at the beginning, plasma cutters are a great option because of their highly versatile nature. Not only can you cut with it, but you can also bevel, gouge, mark, and even weld! No other tool in your metalworking arsenal is so flexible.

6. Plasma is Easy to Use

There are few tools so capable as the plasma cutter that don’t require a formal education or at least detailed instruction and practice before using properly. With plasma, an operator with zero experience can pick up a torch and perform a high-quality cut in seconds. However, if you do have questions, we have the answers to your plasma cutting questions.

7. Plasma Cutting Doesn’t Produce Dangerous Gases

Most plasma cutting is done with compressed air. Nitrogen, argon, and even water are also used to assist with cutting. This is far safer than the acetylene, propylene, and other flammable and volatile gases used in oxy-fuel cutting processes.

8. Plasma is Affordable!

In the past few years, a plethora of economical handheld plasma cutters in the 20A – 100A range have hit the market. Systems that once cost thousands can now be had for hundreds. That puts this technology within reach for even the smallest of fabrication and repair shops.

To look into picking up your own plasma cutter, you can browse our selection of high-grade plasma cutting products from American Torch Tip.

8 Steps to Protect Your Handheld Plasma Cutter

How to Keep Your Handheld Plasma Cutter Running Trouble-Free 

All trade professionals rely on their tools to make a living. Like any piece of equipment, your handheld plasma cutter requires regular preventative maintenance in order to maintain optimal performance. Below are some tips to keep your equipment in tip-top shape. 

1. Keep Plasma Cutters Covered When Not in Use 

This is one of the easiest steps you can take to maintain your handheld cutter when working with plasma. In most fabrication environments, dust, grime, and metallic particles settle and adhere to almost every surface. Just as these can make you sick, they can seriously impair the proper function of your machine. Metallic particles can find their way onto sensitive circuitry and cause expensive and dangerous shorts. Grime may obscure small, easy-to-fix problems which may later turn into big, expensive ones. In order to avoid these scenarios, simply cover your machine when you’re not using it. Many machines have optional fitted covers, but a common drop cloth will suffice. 

2. Turn Off The Air Supply And Purge Your System 

This is a good habit to get into whenever you shut down your handheld plasma cutter for the day. Turning off your air supply and purging the air from your machine and will extend the life of hoses, fittings, valves, regulators, and solenoids and prevent unnecessary wear on your compressor if a leak happens to develop while you are away. Shutting off your compressed air system also serves to reduce fire risk, as atmospheric air is approximately 21% oxygen. When cutting, that oxygen serves to boost the plasma arc. For this same reason, it acts as a powerful oxidizer which can accelerate the spread of a fire. 

3. Hang It Up! 

When you are done working for the day, coil your cutting torch loosely and hang it up off of the floor. Not only is this a good general practice for keeping your work area clean, but it will also prevent your torch from becoming damaged when not in use. 

4. Inspect The Work Lead And Clamp 

Work leads and clamps are often taken for granted. We tend to assume that if the clamp is touching the workpiece or table, it’s doing its job. The truth is that your work lead and clamp serve a very important function in the welding process and they need a little attention from time to time. First, inspect the cable for damage. Then, check the tightness of the connections at the machine and at the clamp. Lastly, ensure that the clamp is clean and the contact surfaces are free of buildup. 

5. Inspect The Cables 

This is just as important for safety as it is for proper function of your equipment. First, unplug your machine. Then start at the back and inspect the power cord for cuts, burn marks, cracks, and any other damage. Ensure that the plug is properly installed and fits tightly into the socket. Then, inspect the torch cable. Look for damage. Ensure the strain relief springs are properly attached. Check to make sure that the connection is secure. 

Pay special attention to the front end of the cable. Most cable damage occurs within six feet of the handle. If you find any damage, repair the cable or replace the torch. 

6. Inspect The Compressor, Air Lines, Regulators, Filters, and Fittings 

The plasma arc is formed by electricity and gas. Your air supply is a crucial part of this combination. In order to ensure that you have an adequate supply of clean, dry air you must regularly inspect all components of your compressor and delivery systems. Start by unplugging the air compressor. Locate the drain valve and drain the moisture from the tank. When no more moisture is present, close the valve.

Then, repressurize the system. Start at the tank outlet and check for leaks and damage to fittings, hoses and components. Work your way to the end of the line. If you suspect any leaks are present, spray soapy water on the line. Bubbles will indicate if a leak is present. Check any downstream regulators and filters to ensure they are clean and set properly. Finally, if your plasma cutter is equipped with an onboard filter element, check it for serviceability and replace it if needed. 

7. Keep Your Machine Clean 

Even if you follow the first tip and keep your machine covered when not in use, eventually debris will find its way in. When you notice that there is an accumulation on and inside your machine, dust it off. Compressed air and a clean cloth work very well for this task. A clean machine is a happy machine! 

8. Clean or Replace Consumables 

This may seem like common sense, but your consumables take a lot of heat. If they are getting long in the tooth, hit them with a wire brush, clean the spatter off, apply a coating of anti-spatter, or replace them. Waiting until your consumables fail to replace them can come back to haunt you in the form of cut defects and lost time. The cost of an electrode and nozzle is small compared to the cost and hassle of botched cuts. 

Following these easy preventative maintenance tips will keep you and your handheld plasma cutter productive and yield better quality cuts with fewer headaches. For more in-depth maintenance, consult your machine’s operator manual or your local welding equipment supplier. 

Keep Up with American Torch Tip For All Your Welding Inquiries

At American Torch Tip, we pride ourselves in providing high quality torches and consumables that can decrease your operational downtime and improve your revenue. For more welding tips and tricks, stay up-to-date with our blog!

Stainless Steel Plasma Cutting

Plasma cutting systems are widely used in fabrication and repair. In recent years, they have naturally become a go-to tool for cutting many different types of material. While plasma cutting systems are capable of cutting any electrically-conductive material, there are certain considerations that must be taken into account when attempting to cut stainless steel. Let’s start by looking at the practicality of plasma cutting stainless steel.

Can a Plasma Cutter Cut Stainless Steel?

A plasma cutting is a great solution for cutting stainless steel. It is a relatively fast process and tends to be a more affordable method. There are a variety of plasma systems to select from to produce optimal results depending on your needs.

Now that you’ve selected a plasma cutter for your stainless steel cutting, let’s decide which gas to use when making your cut.

What Gas Should You Use When Cutting Stainless Steel?

The type of gas used for plasma cutting is one of the primary factors in determining the cut quality and edge finish of the stainless steel plate. Ideally, a high-definition dual-gas plasma cutting system will deliver the best results, however, a single gas system also works.

Single Gas Cutting

1. Air: Depending on the amperage rating of the cutting system, you can use compressed air to cut stainless steel up to about 25mm (2”). A large amount of nitrogen present in air, however, will result in a blackening of the cut edge. Oxygen may also increase the heat-affected zone (HAZ) and degrade edge quality as well.
2. Oxygen (O2): Oxygen may be used to cut stainless steel, but is a less than ideal option as it will cause degradation in edge quality and a larger heat-affected zone (HAZ).
3. Nitrogen (N2): Nitrogen delivers increased cut speed and produces a smoother cut surface but may increase top edge rounding and angularity.

Dual Gas Cutting (recommended)

1. Nitrogen (N2) – Water: Sometimes referred to as Water Mist Secondary (WMS), dual gas cutting with nitrogen and water is economical, produces a clean top edge, and gives a straw-colored cut edge finish. It does, however, necessitate the use of a water table.
2. Hydrogen/Nitrogen (F5) – Nitrogen (N2): This combination produces superior angularity but can only cut material up to about 3/8” in thickness.
3. Hydrogen/Argon (H35) – Nitrogen (N2): This gas pairing will provide a square cut edge with a varying color on thicker material but H35 is not readily available in all markets and excessive dross may result on thin plate.

Other Factors to Consider When Cutting Stainless Steel

Now that you know the different types of gas, let’s discuss how to achieve the best quality cut. There are a variety of ways to maximize your cut quality, efficiency, and safety while plasma cutting stainless steel.

Heat Affected Zone (HAZ)

Heat-affected zone is a concern when cutting a variety of materials, but is of special concern when cutting stainless steel. Most grades of stainless will show drastic signs of temperature change that remain even after the cooling of the material. This may require secondary process pickling or passivation to remove the discoloration left from the heating of the material.

Maximizing Edge Quality

The edge quality of a plasma cut on stainless steel plate will vary and is highly dependent on three factors:

1. Table Condition: The condition of the bed, gantry, rails, bearings, and other components of your plasma table can have a substantial impact on edge quality. Performing regular maintenance on your table will ensure that you receive the best quality cut possible.
2. Cutting / Shield Gases: Different gases or combinations of gases will produce differing cut edges on different thicknesses of stainless steel plate.
3. Material Thickness: As the thickness of the plate increases, any undesirable cut edge effects will be amplified and a change in shielding gas may be necessary.

Bolt Hole Cutting

When mild steel hole cutting on high-end plasma systems, it is often possible to drop in bolts equal or larger in diameter to the thickness of the plate. Precision hole cutting is more difficult on stainless steel plates due to the arc characteristics and dross accumulation. Operators may find it easier to drill bolt holes on a stainless plate, perform secondary processes to square, or clean up holes cut with the plasma torch.

Can You Plasma Cut a Polyethylene Coated Sheet of Stainless Steel?

In food service and medical equipment fabrication, they often use polyethylene-coated sheeting to protect the surface finish of the material. Cutting PE coated stainless steel sheet is possible with plasma. However, you must keep amperage low and use nitrogen as a shield gas.

When you use nitrogen as a shield gas, it prevents the polyethylene from melting or burning. This is an effective way to cut a coated sheet of stainless steel, but the plasma will not be able to cut through if it is coated on both sides. If both sides are coated, then it will prevent the complete plasma circuit.

How to Minimize Dross When Cutting Stainless Steel

Operators who cut mild steel will be familiar with removing at least some dross. However, it is an unpleasant surprise to find that dross is considerably more difficult to remove when cutting a stainless steel plate. Reconfiguring the table slats may help alleviate this issue if it allows the pierce points to fall in between the slats.

If you are welding stainless steel, there are a few additional things to consider.

How to Prevent Contamination of Stainless Steel Plates

You must try not to contaminate the stainless steel plates. Accidental contamination can occur with carbon steel during dross removal, grinding, brushing, or other processes. This can cause rust pockets, staining, and other undesirable effects.

Produce High-Quality Parts by Plasma Cutting Stainless Steel

When considering special requirements of plasma cutting stainless steel, the process can work very well and produce very high-quality parts. If you have questions about plasma cutting stainless steel, contact your local welding supplier or table manufacturer. If you’re interested in plasma cutting, you can read more about our plasma cutting products, to help you improve your cuts & increase efficiency.

How to Evaluate Plasma Cut Quality

Evaluating Plasma Cut Quality

Plasma cutting is a tremendously capable technology, but the quality of your cut can vary.

With minimal training, an operator can employ a plasma cutting system for the accurate and efficient fabrication of any electrically conductive material. In most cases, the cut quality produced by modern plasma cutting systems is very good.

There are, however, a great number of variables which when properly understood and addressed will yield the optimum quality cut. 

Don’t worry, we’ll cover the variables you can use to evaluate the quality of your cut based on your plasma cutting equipment.

Evaluating Kerf Width of Industrial Plasma Cutting Equipment

The cutting process removes a gap of material from the workpiece, known as kerf. In plasma cutting, the amperage of the cut process primarily determines the kerf width. Lower amperages will produce a narrower kerf. Higher amperages will produce a wider kerf. To achieve the best cut quality in terms of kerf width, the lowest amperage should be selected that allows for a complete cut of any given thickness of a material.

Kerf width in plasma cutting can be as narrow as .4mm or as wide as 10mm depending on the amperage of the process. When nesting parts on a CNC machine, kerf width can add up quickly and make a difference in the utilization percentage of the material. 

Bevel is an Important Factor in Cut Quality

Bevel is a top to bottom variation from perpendicular on the cut edge. Positive bevel indicates that the bottom edge of the cut is protruding. Negative bevel indicates that the top edge of the cut is protruding. In plasma cutting, improper cut height is the most common cause of unintended bevel. When the cut height is too high, a positive bevel will appear. When the cut height is too low, a negative bevel will appear. When a plasma cutting system is operating optimally, bevel on the “good side” of a cut may be less than 1°.

If cut parameters are off, or if there is a problem with the system, bevel may exceed 6°. If you are experiencing an extreme bevel, you should ensure that your torch moves in the correct direction relative to the part being cut. The “good side” of the cut will be the right side of the direction the torch is moving.

When CNC cutting, the torch must also be square to the plate to avoid unintended bevel. Similar to bevel, a condition called undercut may also develop when cut height is too low. A concave edge on the cut part, usually closest to the top edge, indicates an undercut. 

Don’t Forget to Evaluate the Quality of Your Edge Rounding 

Edge rounding is the slight melting that occurs at the edge of a cut part. It is similar to bevel, but takes a rounded shape instead of a sharp one.

Top edge rounding occurs most commonly when cut height is too high. While some top edge rounding is normal when plasma cutting, it can become excessive due to a number of factors including worn consumables, improper cut height, and incorrect gas pressures. Arc density also has a large effect on top edge rounding. The more dense the plasma arc is, the less likely top edge rounding is to occur.

Sometimes, rounding can occur on both the top and bottom edges of the material. This usually occurs when you apply too much current (amperage). You can remedy this by selecting a lower current process. 

Dross / Spatter is an Important Quality-determining Factor for Industrial Cutting Equipment

At the edge of a cut, the re-solidified metal forms dross. There are two major varieties of dross: High speed dross and low speed dross. High speed dross is hard and light and accumulates on the top edge of the material. Low speed dross is thick and bubbly and accumulates at the bottom edge of the material.

As their names imply, both of these types of dross develop as a result of cut speed. When cut speed is too low, the plasma arc begins to widen and molten material is no longer completely discharged from the cut path. This type of dross is undesirable but fairly easy to remove. When cut speed is too high, the arc begins to lag behind and leaves a trail of material which has rolled over the top edge of the cut in the form of high speed dross. High-speed dross is much more difficult to remove and will usually require a secondary operation such as grinding.

Besides dross, the plasma cutting process also causes spatter. Spatter is when the molten material is ejected from the cut due to the swirling of gas that lands on top of the workpiece or torch. Once it cools, you can easily remove the spatter. The use of an anti-spatter solution on the workpiece or torch can prevent spatter from adhering and make it even easier to remove if it sticks. 

Look at Lag Lines in Your Cuts 

Lag lines are small vertical ridges on the cut edge. They indicate the path of the plasma arc as it moves through the material from top to bottom. When cutting with air plasma, the lines should be nearly vertical (perpendicular to the surface). When cutting with oxygen, the lag line should lead slightly. When cutting with nitrogen or argon/hydrogen, the lag lines should trail slightly. If cut-speed is too fast, lag lines will take on an “S” shape. Lag lines are a great indicator of whether or not your cut speed is set appropriately. 

Finally, Evaluate The Surface Finish 

Surface finish of plasma cut parts can be highly variable. Some cuts will be smooth and glossy. Others may be rough, jagged, or inconsistent. The type of material that is cut, the gases used in the cutting process, or the cutting process itself can all affect the surface finish. In CNC cutting, there are two categories of induced roughness: Those induced by the process (worn or damaged consumables, improper gas flow, etc.) and those induced by the machine (dirty rails, worn bearings, improper alignment, etc.). If cut edge irregularities are consistent through the process, you may have a process deficiency. If cut edge irregularities only appear on one axis, you may have a machine deficiency. 

It is important to note that cut quality is subjective. What one person may consider a defective cut, another may deem perfectly acceptable for its intended application. Cut quality is weighed in the balance against cut speed, intended use, and the potential use of the equipment. After all, a perfect cut edge does not mean much if the parts are not produced in time. 

If this guide was helpful, we wrote plenty of blog posts with in-depth information about plasma cutting, just for you! For example, we recently wrote a blog to help you avoid unintended plasma cutting issues.

How to Improve Mechanized Plasma Consumable Life

Could you have imagined it, melting the stiffest materials with a gash of the brightest element? A plasma cutter makes it happen. It works more effectively than all other cutters out there.

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What is Plasma? Your Beginners Guide

Plasma cutters are so accessible and easy to use that we take the science behind them for granted. So, what is plasma, really?

Most of us learned in high school that there are three states of matter and as energy is applied to a substance it changes state from a solid to a liquid, to a gas. Well, that’s not where the story ends.

What is Plasma?

If a gas becomes superheated, the fourth state of matter (plasma) can occur. When this happens, electrons become stripped from protons and atoms forming an ionized gas and become free.

This allows plasma the potential to become electrically charged. Plasma will also produce and respond to magnetic fields.

These properties of plasma make it very powerful, but also very controllable.

How Common is Plasma?

Despite being relatively unknown and misunderstood by most of us, plasma is actually very common. How common? 99.9% of all mass in the universe is plasma.

It’s everywhere.

As a matter of fact, Earth is one of only a handful of known planets where the other three states of matter even exist.

Examples of Plasma

Lightning

A lightning bolt is a large and powerful atmospheric electrostatic discharge that produces around a gigajoule of energy. That’s about enough to power the average US home for 9 days!

Lightning is visible in the form of radiant heat created through the rapid disposition of electrons in the atmosphere.

Stars

Most stars are formed entirely of plasma. They are so hot that atomic bonds will not hold, and molecules remain ionized.

Stars are the most powerful known examples of plasma, with the ability to project heat energy and electromagnetic radiation for hundreds of millions of miles!

Neon & Fluorescent Light Bulbs

Neon and fluorescent light bulbs use a gas sealed inside a tube or coil which is excited by the introduction of alternating current to emit light. If a strong enough electromagnetic field is present, these bulbs can even be illuminated without being plugged in!

Plasma Televisions

Plasma TVs have largely been replaced by newer LED models, but they were the pinnacle of picture quality in the early 2000s. They work by using a series of tiny red, green, and blue light cells which are essentially tiny plasma spheres.

Aurora Borealis

While still not fully understood, it is generally accepted that the Northern Lights are caused by solar winds carrying energy that interact with the magnetic field found near the North Pole of Earth. This ionizes atmospheric gas and creates a beautifully colored plasma that is visible for hundreds of miles.

There is also a Southern counterpart near the South Pole, however relatively fewer people live near the South Pole, so this event is lesser known.

Elmo’s Fire

St. Elmo’s fire is named after Saint Erasmus of Formia (a.k.a. Saint Elmo), the patron saint of sailors. It is a natural phenomenon when a tapered protrusion (often from a ship’s mast) reacts with nitrogen in the atmosphere under a very specific set of conditions to create a small blue corona of plasma.

Plasma Globe

Many of us have seen this toy as children without actually realizing what it was. A plasma globe is a glass sphere filled with various noble gases which has a high-voltage electrode placed conspicuously in the center.

When voltage is applied, the gases become excited and electrical filaments form amidst the plasma between the electrode and the outer glass insulator. It was invented by none other than Nikola Tesla, who called it an “inert gas discharge tube”.

If you are standing on the ground and touch one with your bare hand, the filament will become attracted.

Lightsabers

Although lightsaber science has a foundation in the Star Wars universe and not our own, according to Wookieepedia a lightsaber consists of a plasma blade emitted by a kyber crystal.

Plasma cutting torches use the plasma to conduct an electrical arc from an emitter to the workpiece where it transfers massive amounts of heat energy to a precise point to melt the material being cut. The plasma is typically swirled to create stability, just as a quarterback would throw a football.

Think of a lightning bolt inside a tornado, all placed conveniently in the palm of your hand and ready to melt metal at the push of a button.

Get High-Quality Plasma Cutters From American Torch Tip

Want cleaner, faster cuts? Our cutters have a more stable plasma arc and electrodes that last 2x longer.

Additionally, our technology has the ability to reduce the usage of your consumables by 25% or more, increasing their lifespan and saving you money.

We have multiple lines of durable plasma cutters including our PHD® and PHDX®,  CleanCut™, and HelioCut™. Speak to one of our experienced staff members to see which one is right for you.

For more information on plasma cutting, take a look at ATTC’s selection of plasma cutting products.

Experiencing issues with your plasma cutter? Read our Plasma Troubleshooting Guide.

5 Things to Check Before You Replace Your CNC Plasma Consumables

Do You Need to Replace Your CNC Plasma Consumables?

As your plasma cutting jobs progress, you may start to notice your cut quality diminishes. CNC plasma cutting is used for precise applications, so it’s important that you maintain your plasma consumables to extend the life of your torch.

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The History of Plasma Cutting: The Evolution of Plasma Cutting

In the world of modern metal fabrication, plasma cutting is ubiquitous. The low cost, ease of use, and capabilities of plasma cutting systems make them practical for a wide variety of everyday uses. That hasn’t always been the case, however.

Keep reading to learn the history of plasma cutting and what we are doing today!

Plasma Cutting Timeline

Plasma cutting has come a long way over the years from its original creation in 1957. Which is lucky for us.

New technology has been invented and perfected to make plasma cutting more efficient and cost-effective.

How Plasma Cutting Evolved to the Current-Day State:

In order to fully appreciate how far plasma cutting technology has come, we have to first look at where it all began. Back before there were cordless phones or even zip ties, Dr. Robert Gage invented plasma cutting.

(Plasma Cutting History Flowchart: click to enlarge)

As you can see, over the past sixty-four years, plasma cutting systems have become more capable, less expensive, and far easier to operate. Cut speed and quality are far above and beyond what Union Carbide could have imagined in 1957.

Cutting systems that once took up an entire room may now be slung over an operator’s shoulder and carried up a ladder. Technology that once only the largest of corporations could afford is now priced affordably to even the most price-conscious of consumers. Oxy-fuel torches, once a go-to, now collect dust in many fabrication and repair shops.

Plasma Cutting Present

Now in 2022, we have an expansive line of plasma cutting technology including our Heliocut™ Consumables, CleanCut™ Consumables, and PHD™ and PHDX™ Torches.

Our consumable technology is changing the game of plasma cutting tips by reducing plasma arc turbulence with a high-velocity configuration and stabilizing and accelerating the gas column.

Plasma cutting has never been easier with consumables and torches that allow you to produce ultra-smooth cuts with less than 2º bevel. Additionally, our current consumables are made to double the life of your consumables and torches to reduce downtime and save you money.

The Future of Plasma Cutting

What will the future bring for plasma cutting technology? Nobody knows, but it is a safe bet to say that this shop staple isn’t going to disappear anytime soon.

Learn more about our plasma cutting technology’s unmatched capabilities and make the switch today!

To learn more about plasma cutting technology you can read our welding blogs or checkout out our Plasma Troubleshooting Guide!

The 5 Types of Plasma Bevel Cuts

There are many different types of plasma cuts and each one requires different processes and tools. If you do it wrong it can cost you lots of time and money, cutting into your profits.

In this article, we will explain the different types of plasma cuts and their proper tools, including the 5 different types of bevel cuts.

Let’s dive in.

Straight Cutting

Most plasma cutting is done with the torch positioned 90° perpendicular to the workpiece. This is called “straight” or “I” cutting. In this process, any bevel is considered undesirable and most operators will attempt to mitigate that by monitoring the performance of their machine and making sure all the parameters are properly set to get a square-edged cut.

Even under the best conditions, a bevel of up to 2° is usually considered acceptable, although it is possible to achieve a bevel of less than 1° using technology such as Clean Cut.

Using Bevel Cuts

Sometimes, however, a bevel is required. If the part being cut is thick and must be fitted and welded, a bevel will assist with fit-up and ensure that the weld is able to fully penetrate the workpiece and achieve a proper joint.

Traditionally, this was done with an oxy-fuel torch, a grinder, or other secondary processes. Today, CNC plasma systems are capable of producing high-quality beveled edges at the same time that they profile the plate.

Different Types of Bevel Cuts

There are five types of plasma bevel cuts, represented by the letters A, K, V, X, and Y. These letters are a fairly accurate representation of the cross-section profile of the part after it has been cut.

A Bevel

An “A” bevel cut is the most common type of bevel. It requires only a single pass of the torch and leaves a cut edge that protrudes on top.

K Bevel

A “K” bevel is the most complicated profile to cut, as it requires three passes of the torch to complete. It is a combination of a top Y and a bottom Y which leaves a vertical land in the middle of the cut.

V Bevel

A “V” bevel is basically an inverted “A” cut. It also requires one torch pass. The cut will protrude on the bottom edge.

X Bevel

An “X” bevel is a combination of an A bevel and a V bevel where the mid-point of the two cuts meets in the middle of the plate, leaving an X shape. An X bevel cut requires two torch passes.

Y Bevel

A “Y” bevel requires two cuts and comes in two varieties. Top Y will have a V bevel that does not extend all the way through the plate, leaving a vertical face at the bottom. A bottom Y cut will be the opposite, with the vertical face at the top and an A Bevel at the bottom.

Due to the large number of variables involved in plasma bevel cutting, programming can be difficult. Many times a “trial and error” process is needed to dial in a cut program that meets the requirements of production accuracy and quality of the finished cut part without crashing the torch into the workpiece or generating an excessive amount of dross. Special consumables are usually required for bevel cutting processes as well.

Contact American Torch Tip or your local welding supplier if you have questions about bevel cutting with your plasma system.

Cutting in the Right Direction: How Does A Plasma Cutter Work?

Looking to perfect your plasma cutting? The first step to improvement is deepening your knowledge.

In this article, we will discuss:

• How does a plasma cutter work
• The dangers of damaged equipment
• Where you can find high-quality plasma cutting torches and consumable

How Does a Plasma Cutter Work

If you have used a plasma cutter, you have probably noticed that there is a difference in appearance between the two edges of the workpiece after a cut is made. This is due to the direction of the plasma gas swirl, as determined by the swirl ring (baffle), and the tendency of un-ionized gas atoms to be thrown to the outside of the gas stream due to their heavier weight.

The latter has a cooling effect on the nozzle, increasing its lifespan. With most plasma torches, the gas will swirl in a clockwise direction. This means the cut edge quality is better on the right side with respect to the torch direction of travel.

Mirror Cutting

On some high-end plasma systems, swirl rings are available which swirl the gas counter-clockwise and allow for counter-clockwise torch motion, also commonly called “mirror cutting”.

This is typically used when two torches are present on one gantry. The torches are either on opposite sides when cutting the same program on two sheets simultaneously, or on the same side when slitting pieces out of a larger plate.

These systems typically also use a shielding gas or water injection system to further cool the nozzle and shield.

Cutting External Feature

This means you are cutting a feature that is external to the finished part, the outside edge. When doing this you will want to cut in a clockwise path.

Cutting Internal Feature

If you are cutting an internal feature such as a hole, you should cut counter-clockwise. Additionally, you need to cut with an appropriate lead-in and overtravel.

Dangers of Damaged Equipment

If your swirl ring becomes cracked or otherwise damaged, or if debris clogs any of the holes, turbulence may be introduced into your plasma arc. This can cause erratic cutting as the arc loses stability. You may notice a wider kerf, increased bevel angle, edge rounding, or other undesirable defects. Great care should be taken when installing swirl rings not to cause damage or clog gas ports.

Create Clean Cuts With ATTC’s Plasma Cutting Torches

Looking for quality plasma cutting torches to improve your cuts, increase your torches lifespan, and reduce downtime? We’ve got everything you need!

From PHD® and PHDX™ plasma cutting torches to CleanCut™ and HelioCut™ consumables, we can help point you in the right direction.

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What is the Best Process for Removing Dross? 5 Tips for Removing Plasma Dross

Dross is the nemesis of plasma cutting system operators everywhere. It ranges from a mild inconvenience to a downright pain in the you know what. Here are some tips for effective dross mitigation.

What is Dross?

/drôs,dräs/

noun

1. Something regarded as worthless; rubbish.
2. Foreign matter, dregs, or mineral waste, in particular scum formed on the surface of molten metal.

Both of these definitions seem very appropriate with regard to plasma cutting.

What’s better than easily removing dross? Avoiding it altogether. Our first three tips may help you do just that.

Best Process For Removing Dross

1. Use an anti-spatter spray, such as Clean Strike.

Anti-spatter spray is inexpensive, fast, and easy to apply and some formulas are non-toxic and environmentally friendly. This will help inhibit dross from adhering to the plate and make it far easier to remove. Anti-spatter spray can also be applied to torches, table slats, and anywhere else you want to keep clean.

2. Adjust your cut speed.

Cutting too fast or too slow will cause the plasma arc to stretch and can result in dross that is both greater in volume and more difficult to remove. A few inches per minute (IPM) up or down can have a big impact here. Don’t be afraid to make an adjustment to dial in your program and find the sweet spot.

3. Pay attention to your consumables.

The nozzle in particular has a big effect on the shape of your arc. A worn or damaged nozzle can cause the plasma arc to become erratic and lead to lower quality cuts and increased amounts of dross. Nozzles should be replaced when the orifice becomes damaged or out of round.

4. Let it cool.

Dross typically cools quickly and is easier to remove once it does. You also don’t want to be sending hot chips of metal flying around your shop and potentially igniting fuel sources. Letting it cool will also help you remove only the dross without damaging the plate if you are using power tools such as a grinder.

5. Select the right tool.

Here are some commonly used options:

• Putty knife – Cheap, handy, pocket-sized.

• Chisel – Stronger than a chisel. Low-tech, but powerful.

• Hammer – Effective, economical, and unlikely to damage the cut part.

• Needle scaler – Like a chisel on steroids. Highly effective for light dross on large parts. Won’t remove material.

• Slag grinder (Time-saver) – Expensive, but worth it. Produces a perfect surface finish.

• Angle grinder with a flap disc – Highly effective and fast.

• Angle grinder with hard disc – For more aggressive dross removal. Be careful not to gouge the cut part.

• Angle grinder with a wire brush – Works well for light dross. Wear long sleeves.

• Oscillating multi-tool – Good for very light dross.

• Pneumatic die grinder – When equipped with some abrasive discs, this can be a handy, fast option.

Work smarter, not harder. If you find that the dross on your parts is very difficult to remove, you should consider what is causing it and if you are using the most appropriate tool to remove it.

30 seconds with a flap disc vs. 30 minutes of banging away with a hammer can save a lot of time, energy, and money.

Want to mitigate dross and have cleaner cuts? Visit our website or call 800-342-8477 to learn more about our efficient plasma cutting technology.