The first and most important tip is to make sure you choose the right consumables for your system. This sounds like pretty simple, commonsense advice, but you’d be surprised at how many times people accidentally pick up and install the wrong consumables. Many consumables parts look the same, so it’s not surprising that it happens. Double-check to make sure the part numbers you choose match the numbers shown on your system or operator’s manual.
Amperage usually isn’t included in cut charts because the amperage you choose should be based on the amperage of your nozzle. For example, if you are using a 45-amp nozzle, then you should set your system to 45 amps.
Setting the amperage too low will cause the torch to produce low energy density, which can form dross or prevent the plasma arc from fully penetrating the material. If the amperage setting exceeds the consumable’s maximum amperage requirements, the nozzle will wear very quickly and fail. Generally speaking, low-amperage consumables and settings will give you better cut quality, while high-amp consumables and settings will allow you to cut faster.
Using 10-gauge steel as an example, if you want to use an 85-amp air plasma system to cut parts with the best possible cut quality, you should choose low-amperage consumables. However, if you want to cut faster, use the specifications found in the chart for the 85-amp shielded consumables with the understanding that those parts will have more edge angularity.
You should choose shielded consumables if your CNC cutting table is equipped with an ohmic sensing circuit and uses electrical contact with the shield and the material to determine the exact location of the surface. If your CNC machine does not have ohmic sensing, then you should choose unshielded consumables.
Cut height is the ideal height that your CNC machine and height control should maintain once the machine starts cutting and moving forward. If the torch gets more than about 0.005 in. higher than the suggested setting, expect angularity, a wider kerf, dross, and possible warpage on thin materials. If the torch moves closer than this setting, collisions with the material are likely. Additionally, you risk getting metal splatter on the front of your consumable set, which could affect your arc.
On a related note, it’s a good idea to apply a water-based gas metal arc welding (GMAW) antispatter spray onto the tip of your torch once the consumables are installed. This will help prevent metal debris and molten metal from sticking to your consumables or, at the very least, make it easier to remove anything that does stick.
Achieving the proper pierce height is just as critical as proper cut height in ensuring long consumable life. If the height is too low, spatter blown back during piercing can destroy the nozzle after only a few starts. Piercing too high may cause excess pilot arcing and lead to premature nozzle damage. The proper pierce height is one and a half to two times the correct torch-to-work distance.
Found in the Best Quality Settings and Production Settings column of your cut charts, arc voltage measurement is the actual unit of measurement between the electrode inside the torch and the material you are cutting. The longer the plasma arc, the higher the arc voltage. Keep in mind that the voltage setting listed in the manual will provide the correct cut height, assuming your consumables are new. If your consumables are a bit worn, you will likely need to adjust this distance manually.
Also, make sure the height control is calibrated correctly. This is important because the calibration can be off by 15 to 20 volts on some smaller machines.
The first and most important tip is to make sure you choose the right consumables for your system. This sounds like pretty simple, commonsense advice, but you’d be surprised at how many times people accidentally pick up and install the wrong consumables. Many consumables parts look the same, so it’s not surprising that it happens. Double-check to make sure the part numbers you choose match the numbers shown on your system or operator’s manual.
Amperage usually isn’t included in cut charts because the amperage you choose should be based on the amperage of your nozzle. For example, if you are using a 45-amp nozzle, then you should set your system to 45 amps.
Setting the amperage too low will cause the torch to produce low energy density, which can form dross or prevent the plasma arc from fully penetrating the material. If the amperage setting exceeds the consumable’s maximum amperage requirements, the nozzle will wear very quickly and fail. Generally speaking, low-amperage consumables and settings will give you better cut quality, while high-amp consumables and settings will allow you to cut faster.
Using 10-gauge steel as an example, if you want to use an 85-amp air plasma system to cut parts with the best possible cut quality, you should choose low-amperage consumables. However, if you want to cut faster, use the specifications found in the chart for the 85-amp shielded consumables with the understanding that those parts will have more edge angularity.
You should choose shielded consumables if your CNC cutting table is equipped with an ohmic sensing circuit and uses electrical contact with the shield and the material to determine the exact location of the surface. If your CNC machine does not have ohmic sensing, then you should choose unshielded consumables.
Cut height is the ideal height that your CNC machine and height control should maintain once the machine starts cutting and moving forward. If the torch gets more than about 0.005 in. higher than the suggested setting, expect angularity, a wider kerf, dross, and possible warpage on thin materials. If the torch moves closer than this setting, collisions with the material are likely. Additionally, you risk getting metal splatter on the front of your consumable set, which could affect your arc.
On a related note, it’s a good idea to apply a water-based gas metal arc welding (GMAW) antispatter spray onto the tip of your torch once the consumables are installed. This will help prevent metal debris and molten metal from sticking to your consumables or, at the very least, make it easier to remove anything that does stick.
Achieving the proper pierce height is just as critical as proper cut height in ensuring long consumable life. If the height is too low, spatter blown back during piercing can destroy the nozzle after only a few starts. Piercing too high may cause excess pilot arcing and lead to premature nozzle damage. The proper pierce height is one and a half to two times the correct torch-to-work distance.
Found in the Best Quality Settings and Production Settings column of your cut charts, arc voltage measurement is the actual unit of measurement between the electrode inside the torch and the material you are cutting. The longer the plasma arc, the higher the arc voltage. Keep in mind that the voltage setting listed in the manual will provide the correct cut height, assuming your consumables are new. If your consumables are a bit worn, you will likely need to adjust this distance manually.
Also, make sure the height control is calibrated correctly. This is important because the calibration can be off by 15 to 20 volts on some smaller machines.
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