Plasma Cutter – Are You Ready For One? – I’ll Help You Decide
The Plasma Cutter is a GREAT tool to allow you to perform fast & precise cuts in all metals used in welding. Since the 1990’s, it has become affordable to many home users. But the Plasma Cutter is still pretty spendy for most of us. Here’s the “deal”:
1) Plasma Cutters cut virtually anything put in it’s path. 2) They produce CLEAN & PRECISE cuts 3) They can be about 10 times faster than Oxy-Acet. to cut ferrous metals. 4) They also cut STAINLESS!
But be CAREFUL! 1) You’re dealing with VERY high temperatures! 2) The voltages at the working area are higher. 3) For heavier duty units the noise level is enough to need ear-plugs. 4) Wear ALL appropriate safety gear: gloves, goggles, etc.
The “What’s it” part: The Plasma “state of matter” happens when a gas is super-heated via an arc. When driven through the arc under pressure, it becomes “plasma”, & cuts metals like butter. Different gases may be used (including air), depending on what you’re cutting.
“The bottom line”: 1) If you HAVE the money & you will be doing LOT’S of cutting…. 2) AND you NEED very clean and precise cuts…Then GET ONE! 3) BUT remember that MOST beginning & some advanced welders can’t justify the expense, NOR do they NEED one. (at least in the beginning).
Below are some comments about some of the Cutters that are available: It’s your call, to buy or not to buy: * As a beginner, it could probably wait. * If you have the money & KNOW that you would eventually get one, then GET ONE NOW. * In my recent search, the cheapest used one I saw on Craigslist was $700 ($1400 new)(Hypertherm Powermax 600). * From a new Miller model 375 = $1400, to a Miller model 1251 = $4800 (Cuts to 1 1/4″).(via weldersource.com). * Plus a new “Giant Tech 50D” at $465 on sale.(at plasmametalcutter.com).
Shop around, ask your buddies, then get one for YOUR needs and budget! HAPPY CUTTING!
CNC Plasma Cutters – Buying Wisely in Today’s Marketplace
Businesses are always looking to stretch every dollar and get the most from their employees. Today’s economy has employers looking for every nickel. When it comes time to make the investment in a new cnc plasma cutter, quality, durability, versatility and cost are all items that must be carefully considered. We all have choices and are looking for the best we can buy for our money.
Making a capital purchase used to be easy. Know what you are looking for, know what your purchase options are, and have an idea of what you want to spend. Today, we need to make wise decisions and know how it will effect our business plans today and for years to come.
When it comes to buying a quality plasma cutting machine, there are some important questions you need to ask:
Is it durable or heavy-duty to handle rigorous plasma cutting today and for years to come? Answer: A heavy-duty, unitized, fully-welded design is critical and provides the most stable platform for accurate plasma cutting. Being able to handle heavy plate loads (2? and more) and withstand rigorous daily usage is vital. Will you be forced to replace a low-cost plasma cutting machine before you expected to?
How important is accuracy from part to part and plate to plate? Answer: It is critical. The mounting surfaces for guides and racks should be machined in a single set-up to assure the best and highest accuracy or your parts. If your cuts are not accurate, can you afford the time, material and money to do them again?
Will it be flexible enough to handle today’s plasma cutting needs and adapt to your future needs? Answer: It is a must. A flexible design will allow for the addition of table extension and additional torches, allowing the equipment to adapt and grow with your business. Can you afford to own a one trick pony?
Is it fast enough to be productive and profitable? Answer: Digitally controlled high power AC brushless servo motors, helical rack and pinion drives, and top quality linear guides assure speed and precision. Being able to provide substantial increases in productivity due to faster response, shorter pre-flow times and tighter integration with the nesting software, is critical. Is your plasma cutting machine capable of being accurate as well as fast?
Will the manufacturer be there when I have questions or need assistance? Answer: It depends on the company. Be sure you purchase from a company that is fully committed to supporting your plasma cutting operations and has the resources to back it up. The design, construction and service of your CNC plasma cutting equipment has a direct impact on your profitability. Will you have access to on-going support for as long as you own the machine?
Businesses are all trying to save money, cut back, and reduce expenses. Sometimes, however, there is a tendency to focus on the wrong things. While you’re reducing operating and overhead costs, you can’t neglect the larger picture. Even in slow economic times, it can be a mistake to be penny wise and pound foolish.
Buying quality today is never a mistake for your tomorrows.
Can a CNC router equipped with a plasma cutter or laser cut smooth aluminum Diamond Plate?
I would how to cut some designs in aluminum diamond plate, and I was curious to know if a CNC router could do with a laser or plasma torch the job. I know a Water works well, but the price of the machine is currently not in my budget. Thank you!
Due to the high thermal conductivity of aluminum, it needs to cut a lot of laser power, so if you can not afford a water jet, I do not think you can afford either an aluminum laser cutting. However, plasma should work well. and relatively inexpensive systems are available or if your volume is low, it could cost more to send effectively to the work a water jet cutter, and not tie money in a machine, even a low-end CNC plasma cutter will likely cost several thousand dollars.
Many plasma cutting machines advertise claims that they are well built and can last for years to come, but only some are able to hold true to such claims. Plasma cutters that are well built with quality components will be the only ones that last the test of time.
There are several factors to consider when choosing a well quality machine.
Typically speaking, most shop needs require cutting plates with a thickness of 2″ or more for days on end. So it is important to choose an industrial quality table that can withstand constant, rigorous usage
The overall design should be fully-welded design with a large stable base that can support heavy weight. A stable platform or base is key to the cutting process. If the base moves or waivers during cutting you will have trouble achieving the precise cuts you require and the process will begin to consume your time. Choose a professional grade machine with a stable base. It will help ensure accurate and precise cutting to produce professional grade products.
Next, the plasma torch and the torch height control can be critical in determining cut accuracy. You can substantially increase efficiency with a plasma cutter that uses the highest quality automatic servo controlled arc voltage system. You will achieve a faster response, shorter pre-flow times and more precise integration.
Next, the components need to be designed and machined to work together. The rack mount and linear guides must work inclusively together. The spiral rack and pinion and linear drives must integrate smoothly, accelerating with ease and accuracy.
Your nesting application is another important consideration that will harness the full potential of a quality plasma cutter. You need it to be easy to set up and learn, simple and to the point. You don’t want to waste your time with complex applications that you don’t need or are to cumbersome.
Lastly, you should consider the overall expansion for future possibilities based on the features packed into the CNC machine. Does the application package include a combination of configurations and expansion features? A flexible machine package can take you a long way is. Consider your needs, long term intentions and overall goals when choosing a CNC plasma cutting system.
The bottom line is an accurate and durable CNC plasma cutter is the sum of it is parts. Choose a high quality CNC plasma cutter capable of growing to meet your company and client’s changing needs.
Unless you are living beyond your needs, spending a little extra buying a quality machine is typically the best bet.
The magnitude of stress that can be formed from welding can be roughly calculated using:
ET
Where E is Young’s modulus, is the coefficient of thermal expansion, and T is the temperature change. For steel this calculates out to be approximately 3.5 GPa (510,000 psi).
Types
Cracks
Defects related to fracture.
Arc strike cracking
Arc strike cracking occurs when the arc is struck but the spot is not welded. This occurs because the spot is heated above the materials upper critical temperature and then essentially quenched. This forms martensite, which is brittle, and micro-cracks. Usually the arc is struck in the weld groove so this type of crack does not occur, but if the arc is struck outside of the weld groove then it must be welded over to prevent the cracking. If this is not an option then the arc spot can be postheated, i.e., the area is heated with an oxy-acetylene torch, and then allowed to cool slowly.
Cold cracking
Residual stresses can reduce the strength of the base material, and can lead to catastrophic failure through cold cracking, as in the case of several of the Liberty ships. Cold cracking is limited to steels, and is associated with the formation of martensite as the weld cools. The cracking occurs in the heat-affected zone of the base material. To reduce the amount of distortion and residual stresses, the amount of heat input should be limited, and the welding sequence used should not be from one end directly to the other, but rather in segments.
Cold cracking only occurs when all the following preconditions are met:[citation needed]
susceptible microstructure (e.g. martensite)
hydrogen present in the microstructure (hydrogen embrittlement)
service temperature environment (normal atmospheric pressure): -100 to +100 F
high restraint
Eliminating any one of these will eliminate this condition.
Crater crack
Crater cracks occur when a crater is not filled before the arc is broken. This causes the outer edges of the crater to cool more quickly than the crater, which creates sufficient stresses to form a crack. It may form a longitudinal or transverse crack or form multiple radial cracks.
Fusion-line crack
This section requires expansion.
Hat crack
Hat cracks get their name from the shape of the cross-section of the weld, because the weld flares out at the face of the weld. The crack starts at the fusion line and extends up through the weld. They are usually caused by too much voltage or not enough speed.
Hot cracking
Hot cracking, also known as solidification cracking, can occur with all metals, and happens in the fusion zone of a weld. To diminish the probability of this type of cracking, excess material restraint should be avoided, and a proper filler material should be utilized. Other causes include too high welding current, poor joint design that does not diffuse heat, impurities (such as sulfur and phosphorus), preheating, speed is too fast, and long arcs.
Underbead crack
An underbead crack, also known as a heat-affected zone (HAZ) crack, is a crack that forms a short distance away from the fusion line; it occurs in low alloy and high alloy steel. The exact causes of this type of crack are not completely understood, but it is known that dissolved hydrogen must be present. The other factor that affects this type of crack is internal stresses resulting from: unequal contraction between the base metal and the weld metal, restraint of the base metal, stresses from the formation of martensite, and stresses from the precipitation of hydrogen out of the metal.
Longitudinal crack
Longitudinal cracks run along the length of a weld bead. There are three types: check cracks, root cracks, and full centerline cracks. Check cracks are visible from the surface and extend partially into weld. They are usually caused by high shrinkage stresses, especially on final passes, or by a hot cracking mechanism. Root cracks start at the root and extent part way into the weld. They are the most common type of longitudinal crack because of the small size of the first weld bead. If this type of crack is not addresses then it will usually propagate into subsequent weld passes, which is how full centerline cracks (a crack from the root to the surface) usually form.
Reheat cracking
Reheat cracking is a type of cracking that occurs in HSLA steels, particularly chromium, molybdenum and vanadium steels, during postheating. It is caused by the poor creep ductility of the heat affected zone. Any existing defects or notches aggravate crack formation. Things that help prevent reheat cracking include heat treating first with a low temperature soak and then with a rapid heating to high temperatures, grinding or peening the weld toes, and using a two layer welding technique to refine the HAZ grain structure.
Root and toe cracks
This section requires expansion.
Transverse crack
This section requires expansion.
Distortion
Welding methods that involve the melting of metal at the site of the joint necessarily are prone to shrinkage as the heated metal cools. Shrinkage then introduces residual stresses and distortion. Distortion can pose a major problem, since the final product is not the desired shape. To alleviate certain types of distortion the workpieces can be offset so that after welding the product is the correct shape. The following pictures describe various types of welding distortion:
Transverse shrinkage
Angular distortion
Longitudinal shrinkage
Fillet distortion
Neutral axis distortion
Gas inclusion
Gas inclusions is a wide variety of defects that includes porosity, blow holes, and pipes (or wormholes). The underlying cause for gas inclusions is the entrapment of gas within the solidified weld. Gas formation can be from any of the following causes: high sulfur content in the workpiece or electrode, excessive moisture from the electrode or workpiece, too short of an arc, or wrong welding current or polarity.
Inclusions
There are two types of inclusions: linear inclusions and isolated inclusions. Linear inclusions occur when there is slag or flux in the weld. Slag forms from the use of a flux, which is why this type of defect usually occurs in welding processes that use flux, such as shielded metal arc welding, flux-cored arc welding, and submerged arc welding, but it can also occur in gas metal arc welding. This defect usually occurs in welds that require multiple passes and there is poor overlap between the welds. The poor overlap does not allow the slag from the previous weld to melt out and rise to the top of the new weld bead. It can also occur if the previous weld left and undercut or an uneven surface profile. To prevent slag inclusions the slag should be cleaned from the weld bead between passes via grinding, wire brushing, or chipping.
Isolated inclusions occur when rust or mill scale is present on the base metal.
Lack of fusion and incomplete penetration
Lack of fusion is the poor adhesion of the weld bead to the base metal; incomplete penetration is a weld bead that does not start at the root of the weld groove. Incomplete penetration forms channels and crevices in the root of the weld which can cause serious issues in pipes because corrosive substances can settle in these areas. These types of defects occur when the welding procedures are not adhered to; possible causes include the current setting, arc length, electrode angle, and electrode manipulation.
Lamellar tearing
Lamellar tearing is a type of welding defect that occurs in rolled steel plates. It has rarely been an issue since the 1970s because steel produced since then has less sulfur.
There is a combination of causes: non-metallic inclusions, too much hydrogen in the material, and shrinkage forces perpendicular to the face of the plates. The main factor among these reasons is the non-metal inclusions, of which the sulfur is the main problem. Lamellar tearing is no longer a problem anymore because sulfur levels are typical kept below 0.005%.
Some things that are done to overcome lamellar tearing are: reducing amount of sulfur in the material or adding alloying elements that control the shape of sulfide inclusions, such as rare earth elements, zirconium, or calcium. A more drastic option is change the workpieces to castings or forgings because this type of defect does not occur in those workpieces.
Undercut
Undercutting is when the weld reduces the cross-sectional thickness of the base metal, which reduces the strength of the weld and workpieces. One reason for this type of defect is excessive current, causing the edges of the joint to melt and drain into the weld; this leaves a drain-like impression along the length of the weld. Another reason is if a poor technique is used that does not deposit enough filler metal along the edges of the weld. A third reason is using an incorrect filler metal, because it will create greater temperature gradients between the center of the weld and the edges. Other causes include too small of an electrode angle, a dampened electrode, excessive arc length, and slow speed.
References
^ Matthews, Clifford (2001), ASME engineer’s data book, ASME Press, p. 211, ISBN 9780791801550, http://books.google.com/books?id=7nIqrfROowQC&pg=PA211.
^ Bull, Steve (2000-03-16), Magnitude of stresses generated, University of Newcastle upon Tyne, archived from the original on 2009-12-06, http://www.webcitation.org/5lpLTHRZo, retrieved 2009-12-06.
^ Rampaul 2003, pp. 207208.
^ a b Cary & Helzer 2005, pp. 404405.
^ a b c Raj, Jayakumar & Thavasimuthu 2002, p. 128.
^ Bull, Steve (2000-03-16), Factors promoting hot cracking, University of Newcastle upon Tyne, archived from the original on 2009-12-06, http://www.webcitation.org/5lpX2E1S7, retrieved 2009-12-06.
^ a b Raj, Jayakumar & Thavasimuthu 2002, p. 126.
^ Rampaul 2003, p. 208.
^ Bull, Steve (2000-03-16), Reheat cracking, University of Newcastle upon Tyne, archived from the original on 2009-12-06, http://www.webcitation.org/5lpXkrGfA, retrieved 2009-12-06.
^ Bull, Steve (2000-03-16), Reheat cracking, University of Newcastle upon Tyne, archived from the original on 2009-12-06, http://www.webcitation.org/5lpYdb66E, retrieved 2009-12-06.
^ Weman 2003, pp. 78.
^ Bull, Steve (2000-03-16), Welding Faults and Defects, University of Newcastle upon Tyne, archived from the original on 2009-12-06, http://www.webcitation.org/5lpDLc6Iw, retrieved 2009-12-06.
^ Defects/imperfections in welds – slag inclusions, archived from the original on 2009-12-05, http://www.webcitation.org/5lp4O9zyW, retrieved 2009-12-05.
^ Bull, Steve (2000-03-16), Welding Faults and Defects, University of Newcastle upon Tyne, archived from the original on 2009-12-05, http://www.webcitation.org/5lnmtLCCy.
^ Rampaul 2003, p. 216.
^ a b Bull, Steve (2000-03-16), Welding Faults and Defects, University of Newcastle upon Tyne, archived from the original on 2009-12-03, http://www.webcitation.org/5ll21lW3L.
^ a b Still, J. R., Understanding Hydrogen Failures, http://www.aws.org/wj/jan04/still_feature.html, retrieved 2009-12-03.
^ Ginzburg, Vladimir B.; Ballas, Robert (2000), Flat rolling fundamentals, CRC Press, p. 142, ISBN 9780824788940, http://books.google.com/books?id=NeKG76F4KWUC&pg=PA141.
^ Rampaul 2003, pp. 211212.
Bibliography
Cary, Howard B.; Helzer, Scott C. (2005), Modern Welding Technology, Upper Saddle River, New Jersey: Pearson Education, ISBN 0-13-113029-3.
Raj, Baldev; Jayakumar, T.; Thavasimuthu, M. (2002), Practical non-destructive testing (2nd ed.), Woodhead Publishing, ISBN 9781855736009, http://books.google.com/books?id=qXcCKsL2IMUC.
Weman, Klas (2003), Welding processes handbook, New York, NY: CRC Press, ISBN 0-8493-1773-8.
External links
Understanding Hydrogen Failures
Categories: WeldingHidden categories: All articles with unsourced statements | Articles with unsourced statements from December 2009 | Articles to be expanded from December 2009 | All articles to be expanded
Harbor Freight oxygen and acetylene welding and cutting torch just as good as my victor torch
One of the best tools for cutting metal is a plasma cutter. It is effective and convenient to use, and thanks to the latest technology being applied in the area, it is now possible to cut metal with almost laser precision.
A plasma cutter works differently than a conventional welding torch. Rather than using a flame produced from a burning gas in the style of oxy acetylene welding, a plasma cutter uses a jet of inert gas such as compressed air, and then applies a very high voltage charge. The electric charge arcs through the jet of air, and ionizes the gas. The ionized gas reaches extremely high temperature, and becomes what is called plasma.
This highly charged and hot temperature jet of plasma is able to melt through metal at the point of contact without having a massive impact on the surrounding material. This makes a plasma cutter a very precise way of cutting metal.
For small jobs in a workshop where metal is being cut in order to make a bodywork patch, or a replacement panel, plasma cutters are the ideal solution. One of the most important aspects of plasma cutters is that they use an inert gas, meaning that you do not have to worry about storing volatile and explosive gases.
In the past, plasma cutters were a fairly imprecise and blunt means of cutting metal thanks to their large “flame”, however, thanks to advances in the materials and technology used to manufacture plasma cutters, they are now able to produce a much more focused flame. This means that you not only get a more exact and neater cut, but are able to do it with lower power.
Plasma cutters are available from under $1000. You can get a Firepower 12 amp plasma cutter with its own compressor that uses compressed air to create the plasma torch for $998.75. This tool, which is ideal for small jobs in any work shop, is flexible enough to carry out a range of tasks.
With a basic compressor driven plasma cutter, you get a torch with two settings. The pilot arc of plasma is ideal for burning off paint, while when you turn up the power; the cutter is able to cut through sheets of steel an eighth of an inch thick at a rate of around nine inches per minute.
By spending a little more, it is possible to get a more powerful and flexible tool. For less than $1350, you can buy a Lincoln Electric Welders Century 25 Amp Plasma Cutter. This tool is designed for effective auto body repair jobs, and provides a fully earthed cutting arc that removes the high frequency harmonics that are able to damage the complex electronics in a car.
The century 25 amp plasma cutter has its own built in compressor, which has an adjustable regulator to control the size of the actual plasma. This means that you can vary the intensity of the cutting edge of the tool, and deal with metals of different thicknesses up to 3/16″ of milled steel, at an acceptable cutting rate.
At the top end of the plasma cutter market there are complex and powerful tools such as the Miller Auto Arc 4500 Plasma Cutter. This tool, which retails from around $2500, is a much more flexible and powerful cutter than most other models. Its 27 amp power supply, coupled with a strong compressor means that it can deliver a flame hot enough to cut through steel more than half an inch thick at an acceptable rate, and get through most body panel metal like a hot knife through butter.
As with all tools, it is important to select the one that fits in best with your business needs and budget. If you only require a lightweight plasma cutter for occasional jobs in the workshop, then an entry level model is perfectly acceptable, however, if you need to perform regular work requiring the tool, then getting a more robust model is an excellent idea, as the tool will more than pay for itself over time thanks to its reliability and ability to cut through metal much faster and let you get on with work more quickly.
Plasma cutters can cut steel and other metals of different thicknesses using a plasma torch. Plasma can also be used for plasma arc welding and other applications.
Plasma cutters are available in various shapes and sizes. All plasma cutters function on the same principle and are constructed around roughly the same design. Plasma cutters send pressurized gas, such as nitrogen, argon, or oxygen through a small channel. In the center of this channel, you’ll find a negatively charged electrode.
Plasma cutters can cut different shapes in metals properly. It is a very simple and economic technique. With the help of these cutters, the cutting work can be done accurately, in full speed and cut any type of metal in any shape. Due to low level skill, plasma cutters are threat to conventional metalworking tools. Plasma causes the energy to break apart the gas molecules and the atoms begin to split. Generally atoms have protons and neutrons in the nucleus, surrounded with electrons. But in case of plasma cutters, electrons separate from the nucleus. Once the energy of heat releases the electrons from the atom, the electrons begin to move around quickly. If you notice most of the electrons are negatively charged and leave behind positively charged nuclei, known as ions. Electrons crash with other electrons and ions, which releases vast amount of energy, creating plasma and unbelievable cutting power.
Plasma cutters are widely used in auto shops as well as by car manufacturers to customize and create chassis and frames. Even construction companies use plasma cutters in large-scale projects to cut and fabricate huge beams or metal-sheet goods. Locksmiths use plasma cutters to bore into safes and vaults when customers have been locked out.
One major benefit of plasma cutter is that the surface of the metal outside of the cutting area remains relatively cool; this prevents the warping and paint damage that can occur with other flame cutters. A thin heat affected zone also allows the use of templates for precise curved line cutting. Plasma cutters do well as gougers and can pierce metal quickly and accurately.
Plasma cutters are also used in CNC (computer numerically controlled) machinery. The idea behind CNC tables is to allow a computer to control the torch head making clean sharp cuts. Nowadays, CNC plasma equipment can cut thick material, which provides opportunity for complex welding seams on CNC welding equipment that is not possible otherwise. For cutting thinner material, plasma cutter is replaced by laser cutting, due to superior hole-cutting abilities. CNC plasma cutters are also used in HVAC industry. In the present scenario, there is more development in CNC plasma cutting Machinery. In the past, cutting machine was horizontal in shape, but due to improvement in technology, vertical CNC plasma cutting machines are available.
Miller Spectrum 375 X-Treme Plasma Cutter Discounts $$$
Miller Spectrum 375 X-TREME Plasma Cutter, If you are looking for a website that has a huge selection of just about every product you can think of Csn Stores is a great choice. Click Below Discount Welders
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At this moment, CSN Stores, a $200 million company, is comprised of more than 200 different shopping sites under the overall csnstores.com umbrella. Most sites are named for their primary product offerings or the styles they provide. These include: Luggage.com, AllModern.com, WritingDesksAndMore.com, Cookware.com, and BedroomFurniture.com.
Now that CSN has 200+ sites, it also has 400+ employees with several of them working in the service center counseling customers and helping them to find exactly the right item.
The employees at Csn Stores hail from some of the finest colleges in the country, including Bowdoin, Cornell University, Brown University, Boston College, Connecticut College, Bates College, Northwestern University, Hamilton College, Boston University, the University of Massachusetts at Amherst, Emerson College and other fine schools.
Beyond stellar customer service, the 200+ sites at CSN Stores offer the largest selection of items for most home and office goods. And these items are priced right to be very competitive with other sites, providing the customers with strong savings, too. This combination of benefits is rare among online retailers and it does set them apart.
Hello everyone. I am removing the AC from my house (which my high-frequency DC plasma cutter), so I'm worried about a sudden increase in current and the consequences. I like the electronics as a hobby and I am not a professional, but I can assure you all, I'm the right safety precautions. Someone suggested an isolation transformer used and the other has a microwave transformer inductance, or the same triac / relay setup as the microwave. I am on a budget for such a Variac is no question now. Any suggestions?
I would strongly recommend an isolating transformer. In addition to limiting the inductor inrush current, the electrical isolation by the transmitter or you can save from a nasty shock worse. Also Variacs (auto-transformers, which do not provide insulation), can make sense to price was from an electrical storage surplus on a lot. There are also Fero-resonant transformers that provide isolation and a degree of regulation, but that is more than you need or want to spend.
I have a 39 inch round piece of metal that I have a picture in the cutting on a CNC plasma cutter. I want this deposit in a cedar table and I do not know what is with poetry. I thought some type of epoxy, suggestions?
This is commonly done with epoxy flowing. Http: / / www.epoxyproducts.com / bartop.html