Metal Cutting

Plasma

Oxy Fuel
Plasma Arc Cutting (PAC)
is a cutting process that uses an arc and a
high-velocity, ionized gas coming through a
nozzle to cut all metals that can not be cut with
flame
Such as:
Stainless steel
Aluminum
Copper
 PAC
Plasma is a super heated gas that is
ionized.
Ionized- Electrons in the gas have
broken away form their atoms and will
conduct electricity.
Gases used for plasma cutting
includes:
Hydrogen
Argon
Nitrogen and mixture ,plus air and
oxygen
 PAC
How it cuts
The plasma gas (compressed air) is forced
through a nozzle and heated by the arc which
reaches to 5,0000F
 Advantages of PAC
Can cut all metals

Fast cutting speeds

Little distortion from heat

No hazardous gases

Oxygen based system do not leave nitride

deposits

Nitrogen based systems are for aluminum,

stainless steel and nickel
 Disadvantages
Plasma Torch is expensive
Not portable (needs electricity)
Metal fumes created can be a health
hazard
Puts tremendous heat into the metal
around the cut
Creates HAZ
Hardens materials next to the cut
 Safety/ Maintenance
A minimum of a #9 filter shield should be used

Need proper ventilation to remove harmful

gases

Dip electrode into anti-spatter compound

Do not allow Pilot Arc to continue for long

periods of time
 Setting the PAC Torch
If torch amps is set too high travel speed needs to be
increased

Thickness Current Travel Speed

1/16 35 amps 175 in/min
1/8 40 amps 90 in/min
1/4 40 amps 40 in/min
1/4 80 amps 100 in/min
3/8 40 amps 18 in/min
3/8 80 amps 55 in/min
1/2 40 amps 20 in/min
1/2 80 amps 35 in/min
 How to Use
Clean metal
Hook up ground cable
Draw cutting pattern on metal
Hold torch 1/16-1/8 from metal
(torch stand will help maintain this)
Hold torch at a 70 to 90 angle
Pull button when arc begins pull
torch across metal
 Cutting Speed
Too Slow- Molten metal will
collect on bottom of work piece
and need to be ground off (this is
called Dross)

Too Fast- Metal will not be cut all

the way through
Oxy-Fuel Cutting
 Oxy-Fuel Cutting, Welding
Definition:
Burning is the rapid oxidation of a
material
Does Metal Burn?
Virtually all materials will burn if they are first
heated to their ignition temperature.
Steel ignition temp is when it is cherry red,
1300-1400 C
Oxygen burns preheated metal and blows it away from the
work piece.
 Oxyacetylene welding (OAW)
Oxygen and acetylene gas are mixed in the torch tip. The mixture
burns at the torch tip.
The heat from this flame is used to melt the base metal and
welding rod. This melted material forms a weld joint.
OFC Equipment
Combination Cutting Torch with Cutting Attachment

Straight Cutting Torch

Cutting Tips
3690 Cutting Tip

3690-P Cutting Tip

 OFC Cutting Tip
Information
CUTTING TIP SELECTION CHART
Thickness Tip Cutting Oxygen Acetylene Oxygen Acetylene
of Metal Size Orifice Pressure Pressure Consumption Consumption
in Inches Number Drill Size (P.S.I.G.) (P.S.I.G.) (SCFH) (SCFH)
Light gauge
to 3/16 000 #68 15-20 5-15 35-40 10-15
3/16 - 3/8 00 #64 20-25 5-15 45-50 10-15
3/8 - 5/8 0 #60 35-40 5-15 75-85 15-20
5/8-1 1 #56 35-40 5-15 97-107 15-20
1-2 2 #52 40-45 5-15 180-195 20-30
2-3 3 #48 45-50 5-15 270-290 20-35
3-6 4 #42 50-75 10-15 450-600 25-40
 Oxy-Fuel Cutting Set-up

Allset up the same as oxy-fuel welding

except:
To set working pressure for oxygen must
open cutting valve
 Oxy-Fuel Cutting Process
Clean metal
Draw line
Make jig to keep cut straight
Hold tip 1/16-1/8 above metal
Preheat metal to cherry red color
Open oxygen valve and push torch
through metal
(Angle tip slightly toward direction of
cut)
Cutting Flame Types
Carburizing Flame

Neutral Flame

Neutral Flame with Oxygen Cutting Stream

Oxidizing Flame
Advantages
Can cut complex shape
Can cut carbon and low carbon steel
Inexpensive process
Can have multiple cutting torch
Disadvantages
It is slower than other cutting systems
Cut accuracy is not as good as plasma,
water jet ,laser
Creates heat affected zone