Generation of the Plasma Arc (2 Ways):

Plasma cutters produce the plasma in one of two ways: High-Frequency (HF) Contact or Pilot Arcs. Which one your plasma cutter uses depends on how old it is; the new high tech equipments use pilot arcs. The major dissimilarity is that HF Contact models have to close a circuit with a work piece that conducts electrical energy in order to cut while the pilot arc models can cut anything. They work in very different ways.

HF contact method of generating plasma is still found in low financial plan plasma cutters and in older plasma cutters. How it works is the plasma cutting component is connected to the work piece by a clamp and wire and when you touch the nozzle of the torch to the work piece an electric circuit is created. An electric arc zips from the work piece threw the plasma torch nozzle to the negative electrode inside the torch head. At the same time, pressurized inert gas runs in the opposite way, from the torch head out onto the work piece. As the gas surges past the zapping electric arc it is heated to around 50,000 degrees Celsius. At that heat the gas becomes plasma which is a form of matter that is a liquid and a gas at the same time. It is this super hot, super fast moving plasma that cuts the metal. The HF contact technique is said to contain one cycle since the major plasma flow is created in one step.

The Pilot Arc technique is a two cycle procedure. First, a high power, low amperage circuit is used to make a small, high intensity flash in the body of the torch which creates a small pocket of plasma in the torch head (note that the plasma is previously produced in the torch without the required to touch the work piece, this is what eliminates the require for a conducting work piece). Now, you can use a trigger to ignite the main plasma arc that will be used for cutting whatever it is you desire to cut. Pilot Arc is the technique used in CNC plasma cutting applications.

Some Points about Used Plasma Cutters:

1. Knowing the metal thickness that you will cut through earlier is actually helpful when shopping for a used plasma cutter. Knowing your preferred cutting speed is helpful as well. If you require cutting through 3/8" steel at 10 in/minute for example, you’ll find used Everlast plasma cutters very acceptable. If you need to cut through 3/8" steel at 75 in/minute, you will find a used Everlast PowerPlasma 50 plasma cutter satisfactory. Keep in mind that the thicker the metal, the slower the cut and this is true even with high capability cutters. Should you get into a conversation concerning ratings, remember that the normal rate is 10 in/minute.

2. Plasma cutter duty cycles point out a minutes per 10 minutes ratio of a rated capability. If you were to use a machine with a 70% duty cycle for instance, it could run at 400 amps for 6 minutes without having to be cooled. This information is critical when used plasma cutters function in hot surrounds.

3. When looking at your choices of used plasma cutters, make sure you can supply a stable stream of clean and dry air from an excellence air compressor. You will also require ensuring that any air compressor you use is able of satisfying an exacting cutter’s pressure necessities. Every cutter has a different requirement, so do not think that one air pressure is suitable for every cutter. You might find a small cutter with a built in air compressor, but if you are in the market for a big cutter, be ready to seek out an external compressor with a 40 - 60 PSI.

4. Portability is one more significant issue to address. In many cases, a cutter that sits idle for a while is not that big of a deal. A cutter that will be idle for a long time, such as during transportation for example, is a large deal as it can affect the machine’s unit delay.

5. Do not forget to verify that all controls are simply accessible and functioning. All analytic lights should work and consumables (including and air filter and dryer) must accompany the whole machine at either a very little fee or at no charge at all.

6. You will also desire to see if the product’s warranty is still in effect. This will help you get your used plasma cutter serviced. If you can locate the cutter’s producer, and that manufacturer is local and still in business that is even better.

7. Upon closer assessment, avoid buying a used plasma cutter that has broken cables, dirty inside compartments or other visual signs of spoil. These types of signs point out a very short life span and/or expensive repairs down the road.

Plasma Cutter Safety:

There are a little things regarding plasma cutter safety that are different from common welding safety tips. This small list of plasma cutter safety tips is geared toward light duty plasma cutting using compressed air not large manufacturing units that use gas mixtures and water cutting tables.

Electric Shock Can Kill:

- Operating a plasma cutter completes an electric circuit between the torch and the workpiece. The workpiece and something touching the workpiece are part of the electrical circuit.

- Never touch the torch body, workpiece or the water in a water table when the plasma system is working.

Voltages & Currents:

- Plasma cutter output voltages are large amount greater than welding voltages, usually 100-200 volts.

Precautionary Measures:

- Don’t pick up the workpiece, including the waste cutoff, as you cut. Leave the workpiece in place on the workbench with the work wire attached during the cutting process.

- During plasma cutting processes don’t move the work clamp.

- Wear insulated gloves and boots, and keep your body and clothing dry.

- Don’t stand, sit or lie on or if not touch any wet surface when using the plasma cutter system.

- Insulate yourself from work and ground using dry insulating mats or covers large sufficient to prevent any physical contact with the work or ground. If you must work in or near a damp area, use great caution.

What is Plasma?

If you improve a gas to very high temperatures, you obtain plasma. The energy begins to break apart the gas molecules, and the atoms start to split. Usual atoms are made up of protons and neutrons in the nucleus, bounded by a cloud of electrons. In plasma, the electrons divide from the nucleus. Once the power of heat releases the electrons from the atom, the electrons start to move around quickly. The electrons are negatively charged, and they go away at the back their positively charged nuclei. These positively charged nuclei are recognized as ions.

When the fast-moving electrons crash with other electrons and ions, they release huge amounts of energy. This force is what gives plasma its sole status and incredible cutting power.

Compare Plasma Cutter and Oxyacetylene:

Plasma cutter can be perform on some category of conductive metal - mild steel, aluminum and stainless are a few examples. By mild steel, operators will practice faster, thicker cuts than with alloys.

Oxyacetylene cuts by burning throughout the metal and is so limited to steel and other ferrous metals. Plasma cutter produce sufficient power to melt the metal and then creates the momentum to blow it away. Since of this, plasma cutter can cut non ferrous materials, has a lesser ability level and offers sooner travel speeds. In addition, it does not need the use of flammable or explosive resources and is so, safer to work.

The only drawbacks are that plasma cutting machinery is much costly than oxyacetylene, and too, oxyacetylene does not need access to electrical power or compressed air which can create it a more suitable technique for a few users.

Plasma Cutting Technology:

Do you require a cutting instrument for infrequent repair and preservation work? Have you newly embark on a fresh project that requires higher cutting volumes? Or, are you appear for a new option to your present automatic saw? All of these scenarios give huge reasons to examine plasma cutting. With the price of equipment on the refuse, smaller-sized, portable machinery flooding the marketplace and technology offering augmented reimbursement and easier usage -- it might be time to get a serious look at plasma for your cutting applications. The reimbursement of plasma cutting contains simplicity of use, superior quality cuts and quicker travel speeds.

In simplest terms, plasma cutting is superheated, dense air to ionize to shape a conductive gas. This gas conducts electrical energy as of the torch of the plasma cutter to the work part. This is completed throughout a conductive electrode and copper needle on the mechanism, which constrict the high speed gas causing a cyclone result. This provides power to the arc that melt and blows away the metal.

Importance of Plasma Cutting Safety:

It would be a grave mistake to disregard the important of plasma cutting safety. Just because the plasma cutter is easy to use, that doesn’t make it appropriate for haphazard use. Here are some tips to keep you safe while operating one of these machines.

1.Never operate a plasma cutter in a wet environment. You must understand that the plasma cutter uses electricity to start and stay running. Its electrical circuit lies between the torch and the surface being cut. Anything that comes in contact with the object being cut becomes a part of that electrical circuit including water. Okay, especially water since water conducts electricity just like some metals do. So use a plasma cutter in dry environments only.

2.Do not retrieve cut pieces of metal while you’re cutting. Do not remove work pieces while the grand cable is attached. And do not remove a ground clamp while cutting. Doing so places you at high risk for electrocution. For this very reason, insulated boots and gloves are required equipment in any serious place of business.

3.Make sure the ground cable is well secured onto the piece that’s being cut (NOT the piece that will fall off). Arcing near the ground clamp is a sign that the clamp is damaged, unsafe, and needs replacing. Failing to make a safe and secure connection is a sure-fire way to experience electrical shock. The ground clamp must always remain secured prior to releasing a plasma cutter's trigger.

4.Don't use a plasma cutter without proper eye protection. Eye protection isn't just for shielding flying debris. It’s also for shielding against burning. Plasma cutters produce highly intense ultraviolet and infrared waves that can burn the retina, cause cataracts, and damage the skin even if proper precautions aren’t taken.

5.Keep your plasma cutter away from flammable materials. Don’t store or use your cutter near gasoline or other combustible solutions.

6.If you use a heavy duty plasma cutter - that is, one with a excessive noise level, wear ear protection as well.

7.Use a plasma cutter in a well ventilated area. Plasma cutters melt metal and the gases released are toxic.

Flame Cutting - Plasma Cutting Machines Manufacturers

Welders and cutters need good eyesight, good hand-eye coordination, and manual dexterity. They should be able to concentrate on detailed work for long periods and be able to bend, stoop, and work in awkward positions. In addition, welders need to be adaptable, as it is becoming increasingly common for welders and cutters to receive cross-training for other production jobs.

Welders, cutters, and welding machine operators held about 453,000 jobs in 1996. About 9 out of 10 welders and cutters were employed in manufacturing, services, construction, or wholesale trade. The majority of those in manufacturing were employed in transportation equipment, industrial machinery and equipment, or fabricated metal products. All welding machine operators were employed in manufacturing industries, primarily fabricated metal products, machinery, and motor vehicles

Welders and cutters are often exposed to potential hazards. They wear protective clothing, safety shoes, goggles, hoods with protective lenses, and other devices to prevent burns and eye injuries, and to protect them from falling objects.Welders often work in a variety of awkward positions, having to make welds while bending, stooping, or working overhead. In some settings, however, working conditions are much better and there are few hazards or discomforts. Overtime is sometimes necessary to complete special projects.

Cutters also dismantle large objects, such as ships, railroad cars, automobiles or aircraft. Some operate and monitor cutting machines is similar to those used by welding machine operators. Welders and cutters have need good eyesight, good hand-eye to coordination, and manual dexterity.

All welding machine operators were also well employed in manufacturing good industries, primarily fabricated metal products, machinery, and motor vehicles

The Ternary Gas Plasma Weldings Torch

Electron-beam welding has many advantages over other welding techniques. One of the prime advantages of electron-beam welding is the ability to make welds that are deeper and narrower than conventional welds. A second advantage is higher welding speeds, which are due to the high melting rate associated with the concentrated heat source.Electron-beam welding has many advantages over other welding techniques. One of the prime advantages of electron-beam welding is the ability to make welds that are deeper and narrower than conventional welds.

Present-day electron-beam welding is performed in a vacuum chamber, limiting the size of the work piece that can be welded. Maintaining the vacuum requires pumps that use a lot of electricity and special, expensive lubricants that must be disposed of as waste.

Hershcovitch said, This grant provides the opportunity to commercialize the plasma window that I started to design a decade ago. I am very pleased that Acceleron will work on testing it and bringing it to the marketplace. I expect that it will be a commercially successful energy-efficient device.

In present-day technology, an electron-beam welder consists of an electron gun enclosed in a vacuum box that can be as large as a room but is generally much smaller due to efficiency considerations. In contrast, in the new non-vacuum electron-beam welding method, the plasma window is mounted on the electron gun and maintains the small vacuum area needed to propagate the electron beam.

The plasma window is about 40 times as hot as the air at room temperature. This intense heat makes the ionized atoms and molecules move around faster and collide more often with air molecules, thus stopping most of them when they try to cross the plasma window.

Hershcovitch likens the plasma window to the force field window in the shuttle bay area of the Starship Enterprise in Star Trek. The force field separates atmospheric pressure in the Enterprise from the vacuum in outer space. In the plasma window, hot ionized gas particles are trapped by electric and magnetic fields. The particles, like any gas, exert pressure, which prevents air from rushing into the vacuum chamber housing the electron gun.