Plasma cutting is a transformative technique in metal fabrication that uses high-velocity ionized gas to slice through conductive materials with precision. This process, rooted in the principles of plasma physics, harnesses the power of extreme heat, forming a conductive arc that transforms gas into plasma.
Plasma cutting with YesWelder MP200.
Source: https://www.youtube.com/watch?v=R8NWq1yV6dI
By directing a controlled, electrically charged state of matter through a focused nozzle, you can easily cut materials such as steel, aluminum, and other metals. So, understanding how plasma cutting works unlocks a gateway to comprehending the fusion of science, technology, and engineering that drives modern metalworking.
Plasma Cutting Metal Art
Photo by @metalbyrachel (TikTok)
To understand the principles and basics of plasma cutting, we'll first explain the base physics that this process is built around - plasma. Plasma is a fourth state of matter distinct from solid, liquid, and gas. Like other states, plasma is formed once the gasses that make steam are exposed to high energy and become ionized.
Source: https://www.aestheticsystems.nl/en/what-is-plasma
An ionized gas contains positively charged ions and free electrons that result from high energy applied to a gas. When power is added to a gas, its atoms become highly energized and lose or gain electrons, creating a mixture of charged particles. This state generates a conductive and reactive substance capable of conducting electricity, responding to magnetic fields, and emitting light.
Natural examples of plasma include lightning, the aurora borealis, and stars. In everyday life, plasma is found in TVs, fluorescent lamps, neon signs, etc. In technology, plasma is used in various applications, such as plasma cutting, fusion research, certain types of lighting, and plasma displays.
Plasma Densities And Temperatures
Source: https://lasers.llnl.gov/science/understanding-the-universe/plasma-physics
Technological advancements have managed to harness the power of plasma to create the ultimate cutting process known as plasma cutting. Plasma cutting utilizes the fundamentals of the fourth state of matter and the power supply that generates an electric arc.
To cut metal, a gas such as oxygen, nitrogen, argon, or shop air is forced through a small nozzle orifice inside the torch. The plasma cutter generates an external electric arc between the electrode and base piece that heats the pressurized gas, creating an ionized gas known as a plasma jet or plasma stream. This plasma jet can quickly reach temperatures up to 40,000° F, which is more than enough to easily pierce through the workpiece and blow away the molten material.
Plasma Cutting Working Process
Source: https://www.semanticscholar.org/paper/An-Experimental-Study-on-Reducing-the-Formation-of-DeVore/85db70ff2bb416e042e5293834750bfff20f8780
In comparison, the traditional oxyacetylene cutting process reaches temperatures up to 6,000 °F, so plasma arc cutting can be ten times faster. Compared to laser cutting, the plasma cutting process is cheaper, but it has its drawbacks compared to both cutting processes. But we'll talk about them later in the text.
Oxyacetylene Cutting
Photo by @yellowweld (Ins)
To further understand the fundamentals of plasma cutting, we'll explain the essential pieces of the entire plasma cutting process. All elements work in conjunction to create a plasma arc that is stable and hot enough to burn through metal like a knife through butter.
Photo by @metalbyrachel (TikTok)
The essential parts of plasma cutting systems are:
Power supply (Plasma cutters)
Arc starting console
Plasma torch
External gas
Each of these has a vital role in one or another part of plasma cutting, so let's see how they work.
The plasma cutter is a central piece of every plasma-cutting process. The plasma cutter works by converting a single or three-phase AC line voltage into a smooth, constant DC voltage required to form and maintain a plasma arc throughout the process. Plasma cutters such as YesWelder Cut-55 are compact and reasonably priced machines that will provide enough stable energy to create and sustain the plasma-cutting process from start to finish.
CUT-55DS Pro Non-HF Non-Touch Pilot Arc Plasma Cutter
Unlike welders, plasma cutters have few controls or advanced options. You can use them to regulate the current output based on the material type and thickness of the metal you are about to cut. Similar to welders, there are now inverter plasma cutters that can work with 110/220V for different results on various thickness metals.
The arc starting console produces the spark inside the plasma torch to create the electric arc. As the electric arc passes through gas, it becomes plasma, which is fired onto the base metal. Based on the design and internal components, there are several ways to start a plasma arc.
High-frequency start: high-frequency contact is the oldest and cheapest method to start a plasma arc. It is typical for conventional plasma cutters and requires a high voltage and high-frequency spark. High-frequency spark provides enough energy to ionize the compressed gas and form a plasma arc, but it creates "electrical noise." The high frequency can interfere with nearby electronic devices such as phones, computers, and, most importantly, a CNC plasma cutting table, which makes them unsuitable for most applications.
Source: www.drdflo.com
Pilot arc start: The pilot arc method is an advanced technology that allows a spark to form at the torch tip without touching the material. The ability to start an arc without touching the base metal will prolong consumable life when cutting rusty or painted metals. In addition, you don't have to worry about interfering with other electrical devices in your surroundings, which makes it an essential feature for CNC plasma cutters.
Source: https://www.drdflo.com/pages/Guides/Plasma-Cutters-For-CNC.html
Spring loaded start: this plasma arc start is similar to lift TIG. To start an arc, you press your torch into the base metal, and the short circuit and electron flow are established. Once you lift the torch and release the pressure, the spark initiates the pilot arc (non-contact arc). So, there is initial contact with base metal but no contact during the cutting operation.
Photo by @justsomewelds (TikTok)
A plasma torch is your primary cutting accessory or, simply put, your cutting weapon in this application. The torch features several consumable pieces that, in conjunction, start and control the arc through the process while supplying compressed air. In traditional plasma cutting torches, the consumable parts are in contact with one another before initiating an electrical arc. Still, once enough pressure is built up, they are forced apart and create a spark that ionizes the pressured air. The essential parts of a plasma torch are:
Source: https://www.youtube.com/watch?app=desktop&v=kJsn8l0FmTU
Electrode: Plasma torch electrodes are small, narrow pieces that conduct current to create and maintain an arc for plasma-cutting tasks. They receive the electrical current from a cathode block inside the torch and focus the charge through its tip. Electrodes in plasma cutting are considered consumable since they wear over time, and it is recommended to change them simultaneously as a nozzle.
Swirl ring: A swirl ring is a vital consumable that swirls the gas surrounding the plasma arc. Spinning the gas around the nozzle has two essential effects. Firstly, the spinning gas is gyroscopically stabilized like a rifle bullet, making the plasma column less prone to deflect. Secondly, a spinning action centrifugally places the cooler gases on the outside of the nozzle, which protects it from extremely high heat that can damage it.
Nozzle: A nozzle is a consumable with a small opening that controls and directs the plasma arc. Similar to welding torches, there are different sizes, so a nozzle with a larger opening is used for gouging. In comparison, a nozzle with a smaller opening can better direct the gas and so is used for fine, detailed work.
Retaining cap: the retaining cap essentially holds all of the consumable parts of the torch together. Most importantly, the internal cap keeps all the consumable pieces aligned, giving you a reliable and focused arc each time. Keep in mind that this cap can also degrade over time, causing coolant leaks, gas errors, and or poor cut quality.
Shield cap: A shield cap protects the other pieces and internal components of the torch from molten metal and sparks. The shield takes the brunt of the fallout so that wear to other parts is minimized as much as possible.
To create plasma, you must supply an external gas, which is then pressurized inside the nozzle and heated by an arc. Plasma cutters can work with various gases, such as compressed air, nitrogen, argon, hydrogen, and oxygen, or blends of two or three components. Similar to shielding gas, each of these shows different results when cutting.
Compressed air: Air is one of the most popular and widely used plasma-cutting gases, which you are likely to use in your various applications. You'll need a compressor or a plasma cutter with a built-in compressor, such as YesWelder CT2050, an all-in-one welder and cutter. This gas is highly versatile and inexpensive, and it will work well with mild steel, stainless steel, and aluminum on sheet metal and thin gauge up to 1 inch.
YesWelder FIRSTESS CT2050 Powerful 7-in-1 Welder & Cutter
Oxygen: Oxygen is another prevalent plasma gas that is widely used on mild steel in applications that require clean cuts and fast cutting speeds. Cutting arc is hotter than air, so that you can cut mild steel up to 1 1/4" thick. However, higher heat means more damage to consumable parts. Additionally, oxygen is not friendly to shiny surfaces of stainless steel and aluminum.
Nitrogen: Nitrogen is a plasma gas used in heavy-duty applications and thick metals up to 3". It produces quality cuts on most materials, including stainless, mild steel, and aluminum. Nitrogen is often used with several secondary gases, such as air, carbon dioxide, and argon, for thicker material.
Plasma Cutting the 10mm mild steel.
Photo by @vanthefabricator (TikTok)
Argon: Argon is an inert gas, which means it doesn't react with the metal surface you are about to cut, which makes it suitable for specific applications. However, argon itself has low conductivity, which makes it rarely used as a standalone plasma-cutting gas. Typically, argon is mixed with hydrogen to create the hottest plasma-cutting flame and some of the cleanest cut.
Now that you understand each piece of the plasma-cutting system, it is time for a quick recap on how plasma cutters work. Firstly, you will have to assemble your torch with all the pieces, including the electrode, swirl ring, nozzle, retaining cap, and shield. Next, connect the plasma cutter to your outlet and gas supply, and ground the piece you are about to cut. Set the amperage according to the metal thickness you are about to weld.
Source: https://www.youtube.com/watch?v=R8NWq1yV6dI&t=38s
Once everything is set up, it is time to cut. Take your torch, and depending on the start type, place it near the base metal or touch it. Once you press the trigger, the entire process is initiated. The gas flows through the torch into the nozzle, and a swirling ring spins it around to promote cooling and direct the gas. Simultaneously, the arc starting console starts an arc by creating the spark inside the torch (high-frequency contact) or on top of the torch (pilot arc).
Once the arc passes through the pressurized gas, it gives it the energy to form a plasma, which is conductive, ionized gas. The plasma jet reaches exceptionally high temperatures, and it is fired through a narrow plasma nozzle opening. The concentrated, hot plasma arc melts the base surface and easily cuts through conductive material. The process stops once you release the torch trigger, including the gas supply and arc.
Photo by @uniquemetalartz (TikTok)
Now, this is the fundamental explanation of how plasma cutting works, but keep in mind that there are two different plasma cutting systems that are based on the same theory. The components are modified to produce different results so we can divide the systems into two groups:
Conventional plasma cutting systems,
Precision plasma cutting systems.
Conventional plasma cutters, or handheld cutters, are the ones you are likely to deal with as a beginner or hobby metal fabrication enthusiast. They are built to provide versatile and economical results with decent cutting capability at lower currents. As a result, these are cheaper cutters, which often include high-frequency contact starts and cutting, with a maximum cutting power of approximately 1 inch and a moderate amount of dross and kerf.
CUT-55DS Pro Non-HF Non-Touch Pilot Arc Plasma Cutter
A precision plasma cutter work, and it is designed for the sharpest, highest quality cuts that are achievable with plasma. They are designed for metal fabrication processes that require the highest precision with minimal kerf, which is done by introducing higher-end elements and parts. They are often part of computer numerically controlled (CNC) plasma cutters and tables that can be programmed to provide the best results, but they come with a price.
CNC Plasma Cutter Table
A plasma cutter can cut all electrically conductive materials, including mild steel, stainless steel, aluminum, brass, copper, etc. Conductive metals allow the formation of an electrical arc between the electrode and the ground, which provides the energy to turn the pressurized gas into a plasma.
As a beginner or hobby metal fabricator, you will likely use your plasma cutter to weld carbon steel. Low carbon steel, also known as mild steel, is one of the most common materials widely used across industries, and you can easily weld it or cut it with an air gas supply.
Photo by @uniquemetalartz (TikTok)
Stainless steel and aluminum might be more challenging to weld, but you can easily cut them with a plasma cutter. You will want to avoid oxygen gas, but you can do it with an air compressor and pieces around the workshop. Brass, copper, and cast iron are used in particular applications, so you probably won't deal with them that often. Still, knowing that you can cut them with a plasma cutter is always a good option.
As noted, plasma cutting is a versatile and cost-efficient process that provides a wide list of advantages, but it also has some drawbacks.
The advantages of plasma cutting are:
: you can cut all conductive metals of various thicknesses, from sheet metal up to several inches.
: due to highly focused and small arc, plasma cutters produce high-quality cuts with low levels of residual scum on the edge of the metal.
It's a gingerbread kind of day on the plasma cutter.
Photo by @Jeremy Rickard chatterson (YesWelder Official Community): Plasma cutting is a fast-cutting process that will allow you to finish your work quickly, which is essential for mass production and large-scale industrial applications.
: plasma cutters can be programmed with a CNC table to produce highly reliable and redundant results with minimal distortions each time.
Metal fire pit by using a plasma cutter with a CNC table.
Photo by @bondweldingllc (TikTok)
: The latest handheld plasma cutters are relatively affordable yet highly functional machines that you simply must have if you are into metal fabrication or own a small garage shop.
The disadvantages of plasma cutting are:
You can only cut conductive metals that will allow electric arc formation.
Cutting thick metals over a few inches is not recommended.
Consumable pieces can be worn quickly.
It can produce fumes, radiation, noise, and sparks while cutting.
The fumes, radiation, noise, and sparks while plasma cutting.
Photo by @diywelder (TikTok)
As a recap of our article, we'll make a comprehensive comparison of the three most popular cutting methods among metal fabricators - plasma cutting, flame cutting, and laser cutting. Understanding the ups and downs of each cutting method will significantly help you choose the most suitable one for your cutting projects.
Flame Cutting
Source: https://www.octalsteel.com/flame-cutting-oxy-fuel-cutting/
Plasma Cutting
Flame Cutting
Laser Cutting
Cutting Thickness
Thin sheet up to several inches
Can cut sheet metal thicknesses to 100-inch material
Typically used for thin sheets or up to 3/8“
Cut Quality
Produces high-quality cuts
Larger HAZ creates lower-quality cuts
Focused arc produces the highest quality cuts
Cutting Speed
High-speed
Medium to low cutting speed
Moderate to high cutting speed
Cutting Materials
Conductive metals
Carbon steel and Wrought Iron
Metal, wood, paper, cork, and some kinds of plastics
Costs
Moderate to low costs
The cheapest method with the highest cost-efficiency
High-cost equipment
Cutting Safety
It can produce sparks, radiation, noise
High heat and radiation
Automated and safe
laser cutting
Source: https://www.xometry.com/resources/sheet/what-is-laser-cutting/
1. How Plasma Cutters Work？
Plasma cutters operate by assembling a torch with components like the electrode, swirl ring, nozzle, retaining cap, and shield. After connecting to power and gas, and grounding the workpiece, set the amperage based on metal thickness. To cut, position the torch and initiate the process by triggering the arc starting console. Gas flows through the torch, creating a conductive plasma when the arc passes through it. The high-temperature plasma jet, generated by the ionized gas, melts the metal, allowing for easy cutting. Release the trigger to halt the process, shutting off the gas supply and arc.
2. What are the types of plasma cutting systems?
Now, this is the fundamental explanation of how plasma cutting works, but keep in mind that there are two different plasma cutting systems that are based on the same theory. The components are modified to produce different results so we can divide the systems into two groups:
Conventional plasma cutters, or handheld cutters, are the ones you are likely to deal with as a beginner or hobby metal fabrication enthusiast. They are built to provide versatile and economical results with decent cutting capability at lower currents. As a result, these are cheaper cutters, which often include high-frequency contact starts and cutting, with a maximum cutting power of approximately 1 inch and a moderate amount of dross and kerf.
A precision plasma cutter work, and it is designed for the sharpest, highest quality cuts that are achievable with plasma. They are designed for metal fabrication processes that require the highest precision with minimal kerf, which is done by introducing higher-end elements and parts. They are often part of computer numerically controlled (CNC) plasma cutters and tables that can be programmed to provide the best results, but they come with a price.
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