The life of plasma cutter consumables depends on the number of cut starts and stops, cutting amperage, cutting speed, air quality, and operator skill level.

The number of starts and stops causes more consumable way than actual cutting time. For plasma cutters using air you can expect a consumable life of between 150 to 300 starts until the nozzle in the plasma cutter consumables wears out.

Plasma cutter consumables - The orifice in the cutting torch tip constricts the plasma arc to a very small designed diameter. The plasma gas provides a thin cooling boundary layer between the arc and the nozzle. If the gas flow is too slow or the current level is too high then the arc may short inside the cutting tip. This is called double arcing and it will leave gouges inside the cutting tip and shorten consumable life. The purpose of the orifice is to constrict the plasma arc, and pin point it into a very narrow stream. This constriction focuses the plasma stream and increases the plasma arc temperature. A worn orifice does not constrict the plasma arc as much which results in a lower plasma arc temperature and a wider kerf. Lower temperature means longer cut times and reduced productivity for plasma cutter consumables.

The plasma cuter consumables for higher amperage plasma cutters use different nozzle sizes for different amperage settings. Using the wrong nozzle size on a high amperage plasma cutter will cause premature nozzle wear. Gouging also increases the wear of plasma cutter consumables. Edge starts provide the maximum life for plasma cutter consumables.

It is suggested to try a test cut using high amperage and then adjust the cut amperage and speed get a good quality kerf. It should be possible to adjust amperage to achieve a good quality kerf with minimal slag and in this way increase the life expectancy of plasma cutter consumables..

Arc length will affect nozzle life of plasma cutter consumables. Holding too long an arc will cause premature nozzle wear reducing the useful life of the plasma cutter consumables..

Make sure the air supply is clean and dry contaminated air can shorten consumable life in cause premature Plasma cutter consumables torch failure.

After some practice the plasma cutter operator should be able to achieve a skill level that maximizes the life of plasma cutter consumables. Adjusting the plasma cutter for optimum current output and is something that is learned through experience.

Plasma Cutter Consumables is a post from: Plasma Cutters

When looking at various plasma cutters for sale considering a used plasma cutter can save some money. There aren't a lot of moving parts in a used plasma cutter or any plasma cutter for that matter. If the electronic starter circuit works ok and the plasma cutter will cut the thickness of metal that the output current is designed for then the electrical and electronics are probably ok. The only moving parts are the cooling fan which should either run continuously or cycle on and off depending on the type of cooling fan circuitry designed into the plasma cutter. The other moving part is the gas solenoid. The solenoid should turn on when the torch trigger is pulled and should run a few seconds after the trigger is released to provide cooling air flow to the cutter torch nozzle. Used plasma cutters can be a good buy if all the circuits are working properly.

Other than the items mentioned is the condition of the torch. The tip and nozzle are consumables and have a great effect on the plasma cutter performance and are easily replaced. Inspect the hose for cuts and abrasion. The hose is replaceable but hose condition should also be considered in the price of a used plasma cutter. The appearance of the used plasma cutter can tell you something about the use. Does it look well cared for or are there signs of abuse. Consider the appearance of used plasma cutters before the purchase.

Buying a used plasma cutter can save some money but there are other considerations too. If the used plasma cutter is too old then what technology is it missing? Improvements in starting circuits, and other factors should also be considered when looking to buy used plasma cutters.

Used Plasma Cutter is a post from: Plasma Cutters

Plasma Cutters for sale. At Plasma Cutters.net we offer a wide selection of both new and used plasma cutters for sale. If you are looking to purchase your first plasma cutter or looking to replace your existing plasma cutter then plasma cutters for sale will have a plasma cutter to suit your needs.

We carry the Hypertherm Powermax line of plasma cutters, the Miller Spectrum line of plasma cutters and the Lincoln Pro-Cut. We also carry Esab, Hobart, and Thermal Dynamics plasma cutters for sale.

When looking for plasma cutters for sale the plasma cutter output amperage determines the thickness of metal that can be cut. Sizing the plasma cutter to the metal being cut is very important. Buying a plasma cutter that is too small for the job will not provide satisfactory results.

Plasma Cutters For Sale is a post from: Plasma Cutters

The Best Plasma Cutter for Home Use

Don't think that a home use plasma cutter is judged by different parameters than an industrial use plasma cutter. The guidelines you should use to select your plasma cutter is back to the basic question. How thick? The thickness of the metal being cut determines the current output of the plasma cutter. I tend to discourage prospective buyers away from buying a 110VAC plasma cutter because of the input power requirements. Operating at 110VAC a plasma cutter will draw twice the current of a machine operating at 220VAC.

There are two good quality 110VAC plasma cutters that I recommend only if there is a requirement for a highly portable plasma cutter and only if the metal being cut is 1/8th and thinner. A portable plasma cutter with 12 amps output will cut sheet metal and 1/8 material very well. But cutting 3/16th metal is pushing the limit and you won't be happy with the results.

The Miller Spectrum 125C is a nice little plasma cutter for light gauge and thin material. It has a built in compressor so all that is needed is a 110VAC 20 amp circuit to plug into.

The Hypertherm Powermax 190C is also a nice little plasma cutter that also has a built in compressor. It requires a 20 amp 110VAC circuit.

I always recommend a plasma cutter that operates on 220VAC or higher input voltage because the higher the input voltage the lower the input current,

The Best Plasma Cutter for Home Use is a post from: Plasma Cutters

Fit the Plasma Cutter to the Job. A plasma cutter running on 110 VAC draws twice the current of a plasma cutter operating on 230 volts. The Hypertherm 190 C and the Miller Spectrum 125C plasma cutters both operate on 110 VAC. These convenient small output plasma cutters are lightweight portable and have a built in air compressor. Keep in mind that they are suitable for cutting light gauge material. 1/8 inch mild steel and 3/16 inch mild steel are about the maximum thickness these machines will cut and still achieve satisfactory results. A plasma cutter with 12 amp output requires a 20 amp circuit breaker at 110 VAC. That same output current at 230 VAC draws about 8 amps.

The moral of the story is to fit the plasma cutter to the job. The Hypertherm 190C and the Miller Spectrum 125C plasma cutters operate only on 110 VAC. If you expect to routinely cut thicker than 1/8 and 3/16 material then I suggest you'll be happier if you move up to a 230 VAC plasma cutter. Consider the Hypertherm Powermax 30, Miller Spectrum 375, and the Lincoln Pro-Cut 25.

You can also over size the plasma cutter too. Using a monster cutter like a Hypertherm  Powermax 1000 to cut .065 and 1/8 material is definitely not as convenient as using the Hypertherm 190C and Miller Spectrum 125C. I know this from personal experience. Just remember to fit the plasma cutter to the job.

110 VAC Plasma Cutters is a post from: Plasma Cutters

A Few Plasma Cutting Tips

1. Air supply must be Clean, dry, and oil free.
2. Recommended air pressure is best. Increasing air pressure won't help.
3. To start cut touch the work piece gently with the torch.
4. Start the cut on the edge of metal to be cut.
5. Make sure the arc has completely penetrated metal before moving the torch.
6. At the end of the cut, pause to make sure cut is complete.
7. Keep torch perpendicular to the metal surface being cut.
8. Attach ground cable as close to cut as possible.
9. If the arc comes through the bottom of the cut then your cut speed is good.

Follow these plasma cutting tips to achieve nice looking quality cuts.

Plasma Cutting Tips is a post from: Plasma Cutters

What is plasma cutting? The plasma cutting process.

Plasma cutting is a process for cutting metal. Any electrically conductive metal, mild steel, stainless steel, and aluminum can be cut using a plasma cutter. The plasma cutting process uses a stream of compressed air which is passed through an electrical arc in the torch nozzle. The airstream is heated by the electrical arc which causes ionization. At this point the ionized stream becomes plasma. Plasma is electrically conductive and transfers the arc to the work piece. On its way to the work piece the plasma stream is forced through an orifice constricting the stream of heated plasma which further increases its temperature and velocity. The temperature of the plasma at this point is in excess of 30,000 Fahrenheit and the velocity is over 1000 ft./s. The high temperature plasma stream melts the metal. The high velocity stream pushes the molten metal out of the cut.

What is Plasma Cutting is a post from: Plasma Cutters

Best Plasma Cutters

The best plasma cutters are manufactured by Hypertherm, Miller, Lincoln, ESAB, Hobart, and Thermal Dynamics:

1. Hypertherm Plasma Cutter - Provide higher productivity, faster cut speeds, longer consumable life, and ease of operation are hallmarks of the Hypertherm line of Plasma Cutters. Hypertherm Powermax is their plasma cutting line

2. Miller Plasma Cutter - Miller, started as a one man operation in 1929 and is now the world's largest manufacturer of welding and cutting equipment. Miller produces the Spectrum line of plasma cutters.

3. Lincoln Plasma Cutter - Lincoln builds the high quality Pro-Cut plasma cutting systems. Innovations such as Vortech technology, and Parts in Place safety indicator adds value to plasma cutting products.

4. ESAB Plasma Cutter - One of the largest plasma cutting equipment manufacturers world wise, ESAB offers a wide selection of plasma cutters for the industrial market. ESAB products are built to withstand rugged use in the industrial and construction markets.

5. Hobart Plasma Cutter - Hobart is owned by the same company that owns Miller Electric. The Hobart plasma cutter line consists of the AirForce 250ci, AirForce 500i, and AirForce 700i models.

6. Thermal Dynamics Plasma Cutter - A pioneer in the plasma cutting industry manufactures a full range of manual and automated plasma cutting systems. Thermal Dynamics builds the UltraCut, Cutmaster, AirCut, Drag- Gun and PakMaster series of plasma cutters. The Drag-Gun models have built in air compressors and cut up to 1/2 inch material.

Best Plasma Cutters is a post from: Plasma Cutters

The first step in plasma cutter eye protection is to read the operators manual.

The plasma arc cutting process results in:

1. Radiant energy that can harm the eyes in the form of very bright light.
2. Radiant energy in the form of heat that can harm the eyes.
3. Molten metal discharged from the kerf that can harm the eyes.

Eye protection must be adequate to protect the eyes from the bright light, heat, and metal spatter. The following is exerpted from the OSHA regulations.

OSHA Eye and Face Protection

1910.133(a)(5)

The employer shall ensure that each affected employee uses equipment with filter lenses that have a shade number appropriate for the work being performed for protection from injurious light radiation. The following is a listing of appropriate shade numbers for various operations.

           Filter Lenses for Protection Against Radiant Energy

Plasma Arc Cutting

Light - less than 300 amps requires shade 8

Medium - 300-400 amps require shade 9

Heavy - 400-800 amps require shade 10

Plasma Cutter Eye Protection is a post from: Plasma Cutters

How to Build a Plasma Cutter

My background is electronics, 22 years in the U.S. Navy as a Cryptologic Technician and then working as a Canon high end copier technician. A plasma cutting system consists of:

1. Power supply
2. Starting circuit
3. Torch
4. Gas supply

The gas supply is the easiest part because there are lots of choices available. If you already have an air compressor then you just need to make sure it supplies enough volume. Plasma cutters use between 4 to 8cfm depending on the current output. The higher power plasma arcs require more CFM. Usually the pressure is between 65 to 90 psi. Don't forget that the air supply needs to be clean, oil free, and dry.

The torch will come from an existing plasma cutter. Making a torch isn't practical. It would be extremely time consuming to make all the parts and the electrode is made of a not so common metal. The type of electrode metal depends on the gas used. Air and nitrogen use the same metal. And one last but not least point about the torch is that the nozzle and electrode are consumable so a ready supply of replacement parts is required.

The starting circuit. This is doable. The starting circuit usually consists of a high frequency source, an oscillator that causes an arc inside the torch nozzle. When the compressed air flows through the arc it is heated to a high temperature and becomes ionized. At this point the gas becomes plasma and will conduct electricity. The arc is transferred from inside the nozzle to the work piece and the high frequency circuit turns off. Another type of starting circuit doesn't use high frequency and shorts inside the torch to start the arc. I think that would be a function of the torch itself.

The power supply is a major component of the plasma cutter. It provides current between about 10 amps up to about 100 amps depending on what size monster plasma cutter you want to build. The more current the more it will cost. The output voltage is somewhere between 100 volts dc to about 300 volts dc. A good power supply will be regulated and filtered to provide a good clean output. Cost to build a power supply depends on what parts you use. New parts, used parts, make your own parts. Cost will probably run around $300 more or less depending on what the current requirements are. More current equals more money.

My opinion about building a plasma cutter. Although it is doable and many ingenious craftsmen and workshop inventors have built plasma cutters I make the following suggestions;

1. Buy a new plasma cutter. The new models have vast improvements in starting circuits, electrode and nozzle design, and consumable life over older models.

2. Buy a used plasma cutter. Even the older units will more than likely be better designed and more efficient than a homebuilt plasma cutter.

3. Buy a non working plasma cutter for parts to build your home made plasma cutter. You will get a lot of useable parts and they will be rated for plasma cutter use and conditions.

4. I understand that some folks just get a kick out of building and there is nothing wrong with that. If you are that type of person then more power to you. I know the feeling of pride and accomplishment will be worth the trials and tribulations of the inventors process. Enjoy!

How to Build a Plasma Cutter is a post from: Plasma Cutters