PLASMA ARC CUTTING

DESCRIPTION

THE PLASMA ARC cutting (PAC) process severs metal by using a constricted arc to melt a
localized area of a workpiece, removing the molten material with a high-velocity jet of ionized gas
issuing from the constricting orifice. The ionized gas is a plasma, hence the name of the process.
Plasma arcs operate typically at temperatures of 18,0000-25,0000F (10,0000-14,0000C).

PAC was invented in the mid 1950's and became commercially successful shortly after its
introduction to industry. The ability of the process to sever any electrically conductive material
made it especially attractive for cutting nonferrous metals that could not be cut by the oxyfuel
cutting (OFC) process. It was initially used for cutting stainless steel and aluminum. As the cutting
process was developed, it was found that it had advantages over other cutting processes for
cutting carbon steel as well as nonferrous metals. These advantages are summarized below.

When compared to mechanical cutting processes, the amount of force required to hold the
workpiece in place and move the torch (or vice versa) is much lower with the "non-contact"
plasma arc cutting process. Compared to OFC, the plasma cutting process operates at a much
higher energy level, resulting in faster cutting speeds. In addition to its higher speed, PAC has the
advantage of instant start-up without requiring preheat. Instantaneous starting is particularly
advantageous for applications involving interrupted cutting, such as severing mesh.

There are notable limitations to PAC. When compared to most mechanical cutting means, PAC
introduces hazards such as fire, electric shock, intense light, fumes and gases, and noise levels
that may not be present with mechanical processes. It is also difficult to control PAC as precisely
as some mechanical processes for close tolerance work. When compared to OFC, the PAC
equipment tends to be more expensive, requires a fairly large amount of electric power, and
introduces electrical shock hazards.

An arc plasma is a gas which has been heated by an arc to at least a partially ionized condition,
enabling it to conduct electric current. A plasma exists in any electric arc, but the term plasma arc
is associated with torches which utilize a constricted arc. The principle feature which
distinguishes plasma arc torches from other arc torches is that, for a given current and gas flow
rate, the arc voltage is higher in the constricted arc torch.

The arc is constricted by passing it through an orifice downstream of the electrode. As plasma
gas passes through the arc, it is heated rapidly to a high temperature, expands, and is
accelerated as it passes through the constricting orifice toward the workpiece. The intensity and
velocity of the plasma is determined by several variables including the type of gas, its pressure,
the flow pattern, the electric current, the size and shape of the orifice, and the distance to the
workpiece.

PAC circuitry operates on direct current, straight polarity. The orifice directs the super-heated
plasma stream from the electrode toward the workpiece. When the arc melts the workpiece, the
high-velocity jet blows away the molten metal to form the kerf or cut. The cutting arc attaches to
or "transfers" to the workpiece, and is referred to as a transferred arc.

The different gases used for plasma arc cutting include nitrogen, argon, air, oxygen, and mixtures
of nitrogen/hydrogen and argon/hydrogen.

PAC torches are available in various current ranges, generally categorized as low power [those
operating at 30 amperes (A) or less], medium power level [30-100 (A)], and high power [from 100-
1000 (A)]. Different power levels are appropriate for different applications, with the higher power
levels being used for cutting thicker metal at higher speeds.

One of two starting methods is used to initiate the cutting arc: pilot arc starting or electrode (or tip)
retract starting.

A pilot arc is an arc between the electrode and the torch tip. This arc is sometimes referred to as
a nontransferred arc because it does not transfer or attach to the workpiece, as compared to the
transferred arc which does. A pilot arc provides an electrically conductive path between the
electrode in the torch and the workpiece so that the main cutting arc can be initiated.

The most common pilot arc starting technique is to strike a high-frequency spark between the
electrode and the torch tip. A pilot arc is established across the resulting ionized path. When the
torch is close enough to the workpiece so the plume or flame of the pilot arc touches the
workpiece, an electrically conductive path from the electrode to the workpiece is established. The
cutting arc will follow this path to the workpiece.

Retract starting torches have a moveable tip or electrode so that the tip and electrode can be
momentarily shorted together and then separated or "retracted" to establish the cutting arc.

EQUIPMENT

Torches

The plasma cutting process is used with either a handheld torch or a mechanically-mounted
torch. There are several types and sizes of each, depending on the thickness of metal to be cut.
Some torches can be dragged along in direct contact with the workpiece, while others require that
a standoff be maintained between the tip of the torch and workpiece.

Mechanized torches can be mounted either on a tractor or on a computer-controlled cutting

machine or robot. Usually a standoff is maintained between the torch tip and workpiece for best
cut quality. The standoff distance must be maintained within fairly close tolerances to achieve
uniform results. Some mechanized torches are equipped with an automatic standoff controlling
device to maintain a fixed distance between the torch and workpiece. In other cases mechanical
followers are used to accomplish this.

PAC torches operate at extremely high temperatures, and various parts of the torch must be
considered to be consumable. The tip and electrode are the most vulnerable to wear during
cutting, and cutting performance usually deteriorates as they wear. The timely replacement of
consumable parts is required to achieve good quality cuts.

Modern plasma torches have self-aligning and self-adjusting consumable parts. As long as they
are assembled in accordance with the manufacturer's instructions, the torch should require no
further adjustment for proper operation.

Other torch parts such as shield cups, insulators, seals, etc. may also require periodic inspection
and replacement if they are worn or damaged. Again, the manufacturer's instructions should be
followed.

Power Supplies

PAC requires a constant-current or drooping volt-ampere characteristic, relatively high-voltage

direct-current power supply. To achieve satisfactory arc starting performance, the open circuit
voltage of the power supply is generally about twice the operating voltage of the torch. Operating
voltages will range from 50 or 60 volts (V) to over 200 volts (V), so PAC power supplies will have
open circuit voltages ranging from about 150 to over 400 volts.

There are several types of PAC power supplies, the simplest being the fixed output type which
consists of a transformer and rectifier. The transformer of such a machine is wound with a
"drooping" characteristic, so that the out-put voltage drops as the cutting current increases.

In some cases, several outputs are available from a single power supply through a switching
arrangement. This switching arrangement can select between taps provided on the transformer or
reactor of the power supply.

Variable output power supplies are also available. The most widely used units utilize a saturable
reactor and current feedback circuit so that the output can be stabilized at the desired current
level.

Other types of controls are available on plasma cutting power supplies, including electronic phase
control and various types of "switch mode" power supplies. The switch mode power supplies
utilize high-speed, high-current semiconductors to control the output. They can either regulate the
output of a standard DC power the so-called "chopper" power supply, or they can be incorporated
in an inverter-type power supply. As new types of semiconductors become commercially
available it can be expected that improved versions of this type of power supply will appear.
Switch mode supplies have the advantage of higher efficiency and smaller size, and are attractive
for applications where portability and efficiency are important considerations.

Cutting Controls

PAC controls are relatively simple. Most manual torches are controlled by a trigger switch. This
switch is pressed to start the cutting arc and released to stop the cut.

For mechanized cutting, starting and stopping the cutting arc can be manual by pushbutton or
automatic by the motion controls of the system. Cutting controls can also sequence the entire
operation, including varying the gas flow and power level if necessary.

Several interlocks are normally used with PAC systems. If the plasma torch is run without an
adequate supply of gas, the torch may be damaged by internal arcing. For this reason, a gas-
pressure switch is usually included in the circuit to ensure that adequate gas pressure is present
before the torch can operate. This interlock will also shut down the torch in the event of a gas
supply failure during cutting.

High-current torches are liquid cooled, and in this case an additional interlock is included in the
coolant system. The interlock prevents operation of the torch without coolant flow and will shut
the power supply off to prevent damage if coolant flow is interrupted during operation.

Motion Equipment

A variety of motion equipment is available for use with plasma cutting torches. This can range
from straight-line tractors to numerically-controlled or direct computer-controlled machines with
parts nesting capabilities. Plasma cutting equipment can also be adapted to robotic actuators for
cutting other than flat plates.

Environmental Controls
The plasma cutting process is inherently a noisy and fume generating process. Several different
devices and techniques are available to control and contain the hazards. One commonly used
approach to reduce noise and fume emissions is to cut over a water table and surround the arc
with a water shroud. This method requires a cutting table filled with water up to the work-
supporting surface, a water shroud attachment to go around the torch, and a recirculating pump
to draw water from the cutting table and pump it through the shroud. In this case, a relatively high
(15 to 20 gpm [55 to 75 L/min]) water flow is used.

Another method, underwater plasma cutting, is also in common use. With this method, the
working end of the torch and the plate to be cut are submerged under approximately 3 in. (75
mm) of water. While the torch is underwater but not cutting, a constant flow of compressed air is
maintained through the torch to keep water out.

The primary requirements in water-table design are adequate strength for supporting the work,
sufficient scrap capacity to hold the dross or slag resulting from cutting, procedure for removing
the slag, and ability to maintain the water level in contact with the work. When the table is used
for underwater cutting, it is necessary to provide a means of rapidly raising and lowering the
water level. This can be accomplished by pumping the water in and out of a holding tank, or by
displacing it with air in an enclosure under the surface of the water.

A cutting table for mechanized or hand plasma cutting is usually equipped with a down-draft
exhaust system. This is vented to the outdoors in some cases, although fume removal or filtering
devices may be required to meet air pollution regulations.

APPLICATIONS

The first commercial application of plasma arc cutting was the mechanized cutting of manway
holes on aluminum railroad tank cars. The process has since been used on a wide variety of
aluminum applications.

Manual plasma arc cutting is widely used in automobile body repair for cutting high-strength low
alloy steel. Instant starting and high travel speeds reduce heat input to the HSLA steel and help
maintain its strength.

The chief application of mechanized plasma arc cutting to carbon steel is for thicknesses up to
1/2 in. (13 mm). The higher cost of plasma arc equipment compared to OFC equipment can be
justified by its higher cutting speeds.

The plasma process has been used for stack cutting of carbon steel, stainless steel, and
aluminum. The plates to be stack cut should preferably be clamped together, but PAC can
tolerate wider gaps between plates than OFC.

Plate and pipe edge beveling is done by using techniques similar to those for OFC. One to three
PAC torches are used depending on the joint preparation required.

CUT QUALITY

Factors to consider in evaluating the quality of a cut include surface smoothness, kerf width, kerf
angle, dross adherence, and sharpness of the top edge. These factors are affected by the type of
material being cut, the equipment being used, and the cutting conditions.

Plasma cuts in plates up to approximately 3 in. (75 mm) thick may have a surface smoothness
very similar to that produced by oxyfuel gas cutting. Surface oxidation is almost nonexistent with
mechanized equipment that uses water injection or water shielding. On thicker plates, low travel
speeds produce a rougher surface and discoloration. On very thick stainless steel, 5 to 7 in. (125
to 180 mm) in thickness, the plasma arc process has little advantage over oxyfuel gas powder
cutting.

Kerf widths of plasma arc cuts are 1-1/2 to 2 times the width of oxyfuel gas cuts in plates up to 2
in (50 mm) thick. For example, a typical kerf width in 1 in. (25 mm) stainless steel is
approximately 3/16 in. (5 mm). Kerf width increases with plate thickness. A plasma cut in 7 in.
(180 mm) stainless steel made at approximately 4 in./min. (3mm/s) has a kerf width of 1-1/8 in.
(28 mm).

The plasma jet tends to remove more metal from the upper part of the kerf than from the lower
part. This results in beveled cuts wider at the top than at the bottom. A typical included angle of a
cut in 1 in. (25 mm) steel is four to six degrees. This bevel occurs on one side of the cut when
orifice gas swirl is used. The bevel angle on both sides of the cut tends to increase with cutting
speed.

Dross is the material that melts during cutting and adheres to the bottom edge of the cut face.
With present mechanized equipment, dross-free cuts can be produced on aluminum and
stainless steel up to approximately 3 in. (75 mm) thickness and on carbon steel up to
approximately 1-1/2 in. (40 mm) thickness. With carbon steel, selection of speed and current are
more critical. Dross is usually present on thick materials.

Top edge rounding will result when excessive power is used to cut a given plate thickness or
when the torch standoff distance is too large. It may also occur in high-speed cutting of materials
less than 1/4 in. (6 mm) thick.

METALLURGICAL EFFECTS

During PAC, the material at the cut surface is heated to its melting temperature and ejected by
the force of the plasma jet. This produces a heat-affected zone along the cut surface, as with
fusion welding operations. The heat not only alters the structure of the metal in this zone but also
introduces internal tensile stresses from the rapid expansion, upsetting, and contraction of the
metal at the cut surface.

The depth to which the arc heat will penetrate the workpiece is inversely proportional to cutting
speed. The heat affected zone on the cut face of a 1 in. (25 mm) thick stainless steel plate
severed at 50 in./min. (21 mm/s) is 0.003 to 0.005 in. (0.08 to 0.13 mm) deep. This measurement
was determined from microscopic examination of the grain structure at the cut edge of a plate.

Because of the high cutting speed on stainless steel and the quenching effect of the base plate,
the cut face passes through the critical 1200 degree F (650 degree C) temperature very rapidly.
Thus, there is virtually no chance for chromium carbide to precipitate along the grain boundaries,
so corrosion resistance is maintained. Measurements of the magnetic properties of Type 304
stainless steel made on base metal and on plasma arc cut samples indicate that magnetic
permeability is unaffected by arc cutting.

Metallographic examination of cuts in aluminum plates indicates that the heat-affected zones in
aluminum are deeper than those in stainless steel plate of the same thickness. This results from
the higher thermal conductivity of aluminum. Microhardness surveys indicate that the heat effect
penetrates about 3/16 in. (5 mm) into a 1 in. (25 mm) thick plate. Age hardenable aluminum
alloys of the 2000 and 7000 series are crack-sensitive at the cut surface. Cracking appears to
result when a grain boundary eutectic film melts and separates under stress. Machining to
remove the cracks may be necessary on edges that will not be welded.
Hardening will occur in the heat-affected zone of a plasma arc cut in high carbon steel if the
cooling rate is very high. The degree of hardening can be reduced by preheating the workpiece to
reduce the cooling rate at the cut face.

Various metallurgical effects may occur when long, narrow, or tapered parts, or outside corners
are cut. The heat generated during a preceding cut may reach and adversely affect the quality of
a following cut.

Electrical

Voltages used in plasma cutting equipment range from 150 to 400 V direct current. Electric shock
can be fatal. The equipment must be properly grounded and connected as recommended by the
manufacturer.

Emergency first aid should be available. Prompt, trained emergency response may reduce the
extent of injury due to accidental electrical shock. Only trained personnel should be permitted to
operate or maintain the equipment. In addition to the manufacturer's instructions, the following
may be of assistance:

(1) ANSI C-2, the National Electrical Safety Code

(2) ANSI Z49.1, Safety in Welding and Cutting

(3) 29CFR1910, OSHA General Industry Standards and NFPA Standard SiB, Fire Prevention in
the Use of Cutting and Welding Processes

Some additional safety items are listed below:

(1) Keep all electrical circuits dry. Moisture may provide an unexpected path for current flow.
Equipment cabinets that contain water and gas lines as well as electrical circuits should be
checked periodically for leaks.

(2) All electrical connections should be kept mechanically tight. Poor electrical connections can
generate heat and start fires.

(3) High-voltage cable should be used. Make sure cables and wires are kept in good repair.
Consult the manufacturer's instructions for proper cable and wire sizes.

(4) Do not touch live circuits. Keep equipment access doors closed.

(5) The risk of electrical shock is probably the greatest when replacing used torch parts.
Operators must make sure that the primary power to the power supplies and the power to the
control circuitry is disconnected when replacing torch parts.

(6) Operators and maintenance personnel should be aware that plasma arc cutting equipment,
due to the higher voltages, presents a greater hazard than conventional welding equipment.

Fumes And Gases

PAC produces fumes and gases which can harm your health. The composition and rate of
generation of fumes and gases depend on many factors including arc current, cutting speed,
material being cut, and gases used. The fume and gas by-products will usually consist of the
oxides of the metal being cut, ozone, and oxides of nitrogen.

These fumes must be removed from the work area or eliminated at the source by using an
exhaust system. Codes may require that the exhaust be filtered before being vented to the
atmosphere.

Several alternative fume removal systems are available for mechanized cutting. One system
consists of two parts, a cutting table which maintains a bed of water that contacts the bottom
surface of the workpiece, and an annular nozzle which generates a water shroud around the arc.

Another system also uses a water bed, but instead of having the level of the water contact only
the bottom surface of the workpiece, the water totally submerges the workpiece. This system is
referred to as underwater cutting and does not require the use of a water-shroud nozzle. It does
require that the level of the water be periodically lowered for loading and unloading the plate,
positioning of the torch and plate, etc. Since the operator cannot see the plate during cutting with
this system, it is intended for use with numerically controlled systems.

There is a possibility of hydrogen detonation beneath the workpiece when cutting aluminum or
magnesium plate on a water table. The actual cause of such detonations is not fully understood,
but they are believed to be due to hydrogen released by the interaction of molten aluminum or
magnesium and water. The hydrogen can accumulate in pockets under the workpiece and ignite
when the cutting arc is near the pocket. Before cutting aluminum or magnesium on a water table,
the equipment manufacturer should be contacted for recommended practices.

Noise

The amount of noise generated by a PAC torch operated in the open depends primarily on the
cutting current. A torch operating at 400 A typically generates approximately 100 dBA measured
at about six feet. At 750 A the noise level is about 110 dBA. Much of the noise is in the frequency
range of 5000-20,000 HZ. Such noise levels can damage your hearing. Hearing protection should
be worn when the noise level exceeds specified limits. These values may vary locally and are
specified by OSHA for most industrial environments.

The water-shroud technique described earlier is commonly used to reduce noise in mechanized
cutting applications. The water effectively acts as a sound absorbing enclosure around the torch
nozzle. The water directly below the plate keeps noise from coming through the kerf opening.
Noise reduction is typically about 20 dBA. This reduction will usually be sufficient to bring the
operation within OSHA limits.

The water-shroud technique should not be confused with water injection or water shielding, since
neither of those process variations use sufficient water to significantly reduce noise.

Underwater PAC provides greater noise reduction than the water shroud because the nozzle end
of the torch and the arc are totally submerged.

Radiation

The plasma arc emits intense visible and invisible (ultraviolet and infrared) radiation. In addition to
potential harm to the eyes and skin, this radiation may produce ozone, oxides of nitrogen, or
other toxic fumes in the surrounding atmosphere.
It is necessary to wear eye and skin protection when exposure to radiation is unavoidable. The
likelihood of radiation exposure may be reduced by the use of mechanical barriers such as walls
and welding curtains. The water shroud will also act as a light-absorbing shield, especially when
dye is added to the water in the table. When the use of dye is contemplated, contact the
equipment manufacturer for information on the type and concentration to use. It is advisable to
provide operator eye protection, even when using these dyes, because of the possibility of
unexpected interruption of water flow through the water shroud.

Underwater plasma cutting reduces the amount of radiation because of the greater depth of the
water. Additional dye is not generally required.

AWS Welding Handbook, Welding Processes, Volume 2, Eighth Edition