Plasma cutting is a process that cuts through
electrically conductive
Electrical resistivity (also called specific electrical resistance or volume resistivity) is a fundamental property of a material that measures how strongly it resists electric current. A low resistivity indicates a material that readily allows ...
materials by means of an accelerated jet of hot
plasma
Plasma or plasm may refer to:
Science
* Plasma (physics), one of the four fundamental states of matter
* Plasma (mineral), a green translucent silica mineral
* Quark–gluon plasma, a state of matter in quantum chromodynamics
Biology
* Blood pla ...
. Typical materials cut with a
plasma torch
A plasma torch (also known as a plasma arc, plasma gun, plasma cutter, or plasmatron) is a device for generating a directed flow of plasma.
The plasma jet can be used for applications including plasma cutting, plasma arc welding, plasma spraying ...
include
steel
Steel is an alloy made up of iron with added carbon to improve its strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistant ty ...
,
stainless steel
Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's corros ...
,
aluminum
Aluminium (aluminum in American and Canadian English) is a chemical element with the symbol Al and atomic number 13. Aluminium has a density lower than those of other common metals, at approximately one third that of steel. It has ...
,
brass
Brass is an alloy of copper (Cu) and zinc (Zn), in proportions which can be varied to achieve different mechanical, electrical, and chemical properties. It is a substitutional alloy: atoms of the two constituents may replace each other with ...
and
copper
Copper is a chemical element with the symbol Cu (from la, cuprum) and atomic number 29. It is a soft, malleable, and ductile metal with very high thermal and electrical conductivity. A freshly exposed surface of pure copper has a pinkis ...
, although other conductive metals may be cut as well. Plasma cutting is often used in
fabrication shops,
automotive repair
An automobile repair shop (also known regionally as a garage or a workshop) is an establishment where automobiles are repaired by auto mechanics and technicians.
Types
Automotive garages and repair shops can be divided into following categor ...
and
restoration
Restoration is the act of restoring something to its original state and may refer to:
* Conservation and restoration of cultural heritage
** Audio restoration
** Film restoration
** Image restoration
** Textile restoration
* Restoration ecology
...
, industrial
construction
Construction is a general term meaning the art and science to form objects, systems, or organizations,"Construction" def. 1.a. 1.b. and 1.c. ''Oxford English Dictionary'' Second Edition on CD-ROM (v. 4.0) Oxford University Press 2009 and com ...
, and
salvage and
scrap
Scrap consists of Recycling, recyclable materials, usually metals, left over from product manufacturing and consumption, such as parts of vehicles, building supplies, and surplus materials. Unlike waste, scrap Waste valorization, has monetary ...
ping operations. Due to the high speed and precision cuts combined with low cost, plasma cutting sees widespread use from large-scale industrial
CNC
Numerical control (also computer numerical control, and commonly called CNC) is the automated control of machining tools (such as drills, lathes, mills, grinders, routers and 3D printers) by means of a computer. A CNC machine processes a p ...
applications down to small hobbyist shops.
The basic plasma cutting process involves creating an electrical channel of superheated, electrically ionized gas i.e.
plasma
Plasma or plasm may refer to:
Science
* Plasma (physics), one of the four fundamental states of matter
* Plasma (mineral), a green translucent silica mineral
* Quark–gluon plasma, a state of matter in quantum chromodynamics
Biology
* Blood pla ...
from the plasma cutter itself, through the workpiece to be cut, thus forming a completed
electric circuit
An electrical network is an interconnection of electrical components (e.g., batteries, resistors, inductors, capacitors, switches, transistors) or a model of such an interconnection, consisting of electrical elements (e.g., voltage sources, c ...
back to the plasma cutter through a
grounding clamp
In electrical engineering, ground or earth is a reference point in an electrical circuit from which voltages are measured, a common return path for electric current, or a direct physical connection to the Earth.
Electrical circuits may be con ...
. This is accomplished by a
compressed gas
A compressed fluid (also called a compressed or unsaturated liquid, subcooled fluid or liquid) is a fluid under mechanical or thermodynamic conditions that force it to be a liquid.
At a given pressure, a fluid is a compressed fluid if it is at ...
(oxygen, air, inert and others depending on material being cut) which is blown through a focused nozzle at high speed toward the workpiece. An
electrical arc
An electric arc, or arc discharge, is an electrical breakdown of a gas that produces a prolonged electrical discharge. The current through a normally nonconductive medium such as air produces a plasma; the plasma may produce visible light. ...
is then formed within the gas, between an electrode near or integrated into the gas nozzle and the workpiece itself. The electrical arc ionizes some of the gas, thereby creating an electrically conductive channel of plasma. As electricity from the cutter torch travels down this plasma it delivers sufficient heat to melt through the workpiece. At the same time, much of the high-velocity plasma and compressed gas blow the hot molten metal away, thereby separating, i.e. cutting through, the workpiece.
Plasma cutting is an effective way of cutting thin and thick materials alike. Hand-held torches can usually cut up to thick steel plate, and stronger computer-controlled torches can cut steel up to thick.
Since plasma cutters produce a very hot and very localized "cone" to cut with, they are extremely useful for cutting
sheet metal
Sheet metal is metal formed into thin, flat pieces, usually by an industrial process. Sheet metal is one of the fundamental forms used in metalworking, and it can be cut and bent into a variety of shapes.
Thicknesses can vary significantly; ex ...
in curved or angled shapes.
The arcs are generated in a three step process. A high voltage spark briefly ionizes the air within the torch head. This makes the air conductive and allows the "pilot arc" to form. The pilot arc forms within the torch head, with current flowing from the electrode to the nozzle inside the torch head. The pilot arc burns up the nozzle, a consumable part, while in this phase. The air then blows the plasma out the nozzle towards the work, providing a current path from the electrode to the work. When the control system senses current flowing from the electrode to the work, it cuts the electrical connection to the nozzle. Current then flows from the electrode to the work, and the arc forms outside the nozzle. Cutting can then proceed, without burning up the nozzle. Nozzle life is limited by the number of arc starts, not cutting time.
History
Plasma cutting grew out of
plasma welding in the 1960s, and emerged as a very productive way to cut sheet metal and plate in the 1980s. It had the advantages over traditional "metal against metal" cutting of producing no metal chips, giving accurate cuts, and producing a cleaner edge than
oxy-fuel cutting. Early plasma cutters were large, somewhat slow and expensive and, therefore, tended to be dedicated to repeating cutting patterns in a "mass production" mode.
As with other machine tools, CNC (computer numerical control) technology was applied to plasma cutting machines in the late 1980s into the 1990s, giving plasma cutting machines greater flexibility to cut diverse shapes "on demand" based on a set of instructions that were programmed into the machine's numerical control. These CNC plasma cutting machines were, however, generally limited to cutting patterns and parts in flat sheets of steel, using only two axis of motion (referred to as X Y cutting).
Safety
Proper eye protection and face shields are needed to prevent eye damage called
arc eye
Photokeratitis or ultraviolet keratitis is a painful eye condition caused by exposure of insufficiently protected eyes to the ultraviolet (UV) rays from either natural (e.g. intense sunlight) or artificial (e.g. the electric arc during welding) ...
as well as damage from debris. It is recommended to use green lens shade #5. OSHA recommends a shade 8 for arc current less than 300 A, but notes that "These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece." Lincoln Electric, a manufacturer of plasma cutting equipment, says, "Typically a darkness shade of #7 to #9 is acceptable." Longevity Global, Inc., another manufacturer, offers this more specific table for eye protection for plasma arc cutting at lower amperages:
Leather gloves, an apron and a jacket are also recommended to prevent burns from sparks and hot metal.
Working in a clean area free of flammable liquids, materials and gases is very important. Sparks and hot metal from a plasma cutter can quickly cause fires if they are not isolated from flammable objects. Plasma cutters can send hot sparks flying up to 5 feet away in certain situations. The operator of the machine is typically blind to any fire that has started because they are behind their face shield.
Starting methods
Plasma cutters use a number of methods to start the arc. In some units, the arc is created by putting the torch in contact with the work piece. Some cutters use a high voltage, high frequency circuit to start the arc. This method has a number of disadvantages, including risk of electrocution, difficulty of repair, spark gap maintenance, and the large amount of
radio frequency
Radio frequency (RF) is the oscillation rate of an alternating electric current or voltage or of a magnetic, electric or electromagnetic field or mechanical system in the frequency range from around to around . This is roughly between the upp ...
emissions.
Plasma cutters working near sensitive electronics, such as CNC hardware or computers, start the pilot arc by other means. The nozzle and electrode are in contact. The nozzle is the
cathode
A cathode is the electrode from which a conventional current leaves a polarized electrical device. This definition can be recalled by using the mnemonic ''CCD'' for ''Cathode Current Departs''. A conventional current describes the direction in whi ...
, and the electrode is the
anode
An anode is an electrode of a polarized electrical device through which conventional current enters the device. This contrasts with a cathode, an electrode of the device through which conventional current leaves the device. A common mnemonic is ...
. When the plasma gas begins to flow, the nozzle is blown forward. A third, less common method is capacitive discharge into the primary circuit via a
silicon controlled rectifier
A silicon controlled rectifier or semiconductor controlled rectifier is a four-layer solid-state current-controlling device. The name "silicon controlled rectifier" is General Electric's trade name for a type of thyristor. The principle of four ...
.
Inverter plasma cutters
Analog plasma cutters, typically requiring more than 2 kilowatts, use a heavy mains-frequency transformer. Inverter plasma cutters rectify the mains supply to DC, which is fed into a high-frequency transistor inverter between 10 kHz to about 200 kHz. Higher switching frequencies allow smaller transformer resulting in overall size and weight reduction.
The transistors used were initially
MOSFET
The metal–oxide–semiconductor field-effect transistor (MOSFET, MOS-FET, or MOS FET) is a type of field-effect transistor (FET), most commonly fabricated by the controlled oxidation of silicon. It has an insulated gate, the voltage of which d ...
s, but are now increasingly using
IGBT
An insulated-gate bipolar transistor (IGBT) is a three-terminal power semiconductor device primarily used as an electronic switch, which, as it was developed, came to combine high efficiency and fast switching. It consists of four alternating lay ...
s. With paralleled MOSFETs, if one of the transistors activates prematurely it can lead to a
cascading failure
A cascading failure is a failure in a system of interconnected parts in which the failure of one or few parts leads to the failure of other parts, growing progressively as a result of positive feedback. This can occur when a single part fails, i ...
of one quarter of the inverter. A later invention, IGBTs, are not as subject to this failure mode. IGBTs can be generally found in high-current machines where it is not possible to parallel enough MOSFET transistors.
The
switch mode topology is referred to as a dual transistor off-line forward converter. Although lighter and more powerful, some inverter plasma cutters, especially those without
power factor correction
In electrical engineering, the power factor of an AC power system is defined as the ratio of the '' real power'' absorbed by the load to the ''apparent power'' flowing in the circuit. Real power is the average of the instantaneous product of v ...
, cannot be run from a generator (that means manufacturer of the inverter unit forbids doing so; it is only valid for small, light portable generators). However newer models have internal circuitry that allows units without power factor correction to run on light power generators.
CNC cutting methods
Some plasma cutter manufacturers build
CNC
Numerical control (also computer numerical control, and commonly called CNC) is the automated control of machining tools (such as drills, lathes, mills, grinders, routers and 3D printers) by means of a computer. A CNC machine processes a p ...
cutting tables, and some have the cutter built into the table. CNC tables allow a computer to control the torch head producing clean sharp cuts. Modern CNC plasma equipment is capable of multi-axis cutting of thick material, allowing opportunities for complex welding seams that are not possible otherwise. For thinner material, plasma cutting is being progressively replaced by
laser cutting
Laser cutting is a technology that uses a laser to vaporize materials, resulting in a cut edge. While typically used for industrial manufacturing applications, it is now used by schools, small businesses, architecture, and hobbyists. Laser cutt ...
, due mainly to the laser cutter's superior hole-cutting abilities.
A specialized use of CNC plasma cutters has been in the
HVAC
Heating, ventilation, and air conditioning (HVAC) is the use of various technologies to control the temperature, humidity, and purity of the air in an enclosed space. Its goal is to provide thermal comfort and acceptable indoor air quality. HV ...
industry. Software processes information on
ductwork
Ducts are conduits or passages used in heating, ventilation, and air conditioning (HVAC) to deliver and remove air. The needed airflows include, for example, ''supply air'', ''return air'', and ''exhaust air''. Ducts commonly also deliver '' v ...
and creates flat patterns to be cut on the cutting table by the plasma torch. This technology has enormously increased productivity within the industry since its introduction in the early 1980s.
CNC plasma cutters are also used in many workshops to create decorative metalwork. For instance, commercial and residential signage, wall art, address signs, and outdoor garden art.
In recent years there has been even more development. Traditionally the machines' cutting tables were horizontal, but now vertical CNC plasma cutting machines are available, providing for a smaller footprint, increased flexibility, optimum safety and faster operation.
CNC plasma cutting configurations
There are three main configurations of CNC plasma cutting, and they are largely differentiated by the forms of materials before processing, and the flexibility of the cutting head.
2-dimensional / 2-axis plasma cutting
This is the most common and conventional form of CNC plasma cutting. Producing flat profiles, where the cut edges are at 90 degrees to the material surface. High powered cnc plasma cutting beds are configured in this way, able to cut profiles from metal plate up to 150 mm thick.
3-dimensional / 3+ axis plasma cutting
Once again, a process for producing flat profiles from sheet or plate metal, however with the introduction of an additional axis of rotation, the cutting head of a CNC plasma cutting machine can tilt whilst being taken through a conventional 2-dimensional cutting path. The result of this is cut edges at an angle other than 90 degrees to the material surface, for example 30-45 degree angles. This angle is continuous throughout the thickness of the material. This is typically applied in situations where the profile being cut is to be used as part of a welded fabrication as the angled edge forms part of the weld preparation. When the weld preparation is applied during the CNC plasma cutting process, secondary operations such as grinding or machining can be avoided,
reducing cost. The angular cutting capability of 3-dimensional plasma cutting can also be used to create countersunk holes and chamfer edges of profiled holes.
Tube and section plasma cutting
Used in the processing of tube, pipe or any form of long section. The plasma cutting head usually remains stationary whilst the workpiece is fed through, and rotated around its longitudinal axis.
There are some configurations where, as with 3-dimensional plasma cutting, the cutting head can tilt and rotate. This allows angled cuts to be made through the thickness of the tube or section, commonly taken advantage of in the fabrication of process pipework where cut pipe can be provided with a weld preparation in place of a straight edge.
New technology
In the past decade plasma torch manufacturers have engineered new models with a smaller nozzle and a thinner plasma arc. This allows near-laser precision on plasma cut edges. Several manufacturers have combined precision CNC control with these torches to allow fabricators to produce parts that require little or no finishing.
The transistors used were initially MOSFETs, but are now increasingly using IGBTs. With paralleled MOSFETs, if one of the transistors activates prematurely it can lead to a cascading failure of one quarter of the inverter. A later invention, IGBTs, are not as subject to this failure mode. IGBTs can be generally found in high current machines where it is not possible to parallel sufficient MOSFET transistors.
Costs
Plasma torches were once quite expensive. For this reason they were usually only found in professional welding shops and very well-stocked private garages and shops. However, modern plasma torches are becoming cheaper, and now are within the price range of many hobbyists, less than $300.
[
see the online seller Amazon, for example.] Older units may be very heavy, but still portable, while some newer ones with
inverter
A power inverter, inverter or invertor is a power electronic device or circuitry that changes direct current (DC) to alternating current (AC). The resulting AC frequency obtained depends on the particular device employed. Inverters do the opp ...
technology weigh only a little, yet equal or exceed the capacities of older ones.
See also
*
Air carbon arc cutting Air carbon arc cutting, also referred to as metal arc gouging, and previously as air arc cutting, is an arc cutting process where metal is cut and melted by the heat of a carbon arc. Molten metal is then removed by a blast of air. It employs a cons ...
*
Laser cutting
Laser cutting is a technology that uses a laser to vaporize materials, resulting in a cut edge. While typically used for industrial manufacturing applications, it is now used by schools, small businesses, architecture, and hobbyists. Laser cutt ...
*
List of plasma (physics) articles
This is a list of plasma physics topics.
A
* Ablation
* Abradable coating
* Abraham–Lorentz force
* Absorption band
* Accretion disk
* Active galactic nucleus
* Adiabatic invariant
* ADITYA (tokamak)
* Aeronomy
* Afterglow plasma
* Airg ...
*
Plasma arc welding
Plasma arc welding (PAW) is an arc welding process similar to gas tungsten arc welding (GTAW). The electric arc is formed between an electrode (which is usually but not always made of sintered tungsten) and the workpiece. The key difference from ...
*
Water jet cutter
*
Welding
Welding is a fabrication (metal), fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing Fusion welding, fusion. Welding is distinct from lower ...
References
External links
HowStuffWorks on plasma cuttingManufacturing Network >> Knowledge Base - What is CNC Plasma Cutting?Plasma Cutter Safe Work Method Statement
{{DEFAULTSORT:Plasma Cutting
Cutting machines
Metalworking cutting tools
Plasma processing
Articles containing video clips
Numerical control