HT Student Workbook Print File - Eng - 893410RevC

Introduction
WelcometothePlasmaCuttingTechnology:TheoryandPracticecourse.UsethisStudentWorkbook
throughouttheclasstofollowalongwiththeinstructorandparticipateinalloftheactivitiesandhands
onexercises.
Aboutthedesignersofthiscourse:Hyperthermdesignsandmanufacturestheworldsmostadvanced
plasmacuttingsystemsforuseinavarietyofindustriessuchasshipbuilding,manufacturing,and
automotiverepair.Itsproductlineincludeshandheldandmechanizedplasmasystemsand
consumables,aswellasCNCmotionandheightcontrols.Hyperthermsystemsaretrustedfor
performanceandreliabilitythatresultsinincreasedproductivityandprofitabilityfortensofthousands
ofbusinesses.TheNewHampshirebasedcompanysreputationforplasmainnovationdatesbackover
40years,to1968,withHyperthermsinventionofwaterinjectionplasmacutting.Thecompany,
consistentlynamedoneofthebestplacestoworkinAmerica,hasmorethan1,000associatesalong
withoperationsandpartnerrepresentationworldwide.Tolearnmore,pleasevisit
www.hypertherm.com.

CourseOverview

Session1: WhatisPlasma?
Session2: UsingPlasmaSystemsinIndustry
Session3: OverviewofaPlasmaSystem
Session4: UsingYourPlasmaSystemOperatorsManual
Session5: OperationofthePlasmaSystem
Session6: EvaluatingCutQualityandTroubleshooting
Session7: TheoryExam
Session8: FreehandandTemplateCutting
Session9: HolePiercingandGouging#1
Session10: Gouging#2andFinalEvaluations

Hypertherm,Inc|Session1:WhatisPlasma? 1
Session1:WhatisPlasma?
Introduction
Slide0:LessonTitle

Slide1:CourseAgenda
Thecourseincludessixlessons,eachofwhich
includesinclassactivities:
1. WhatisPlasma?
2. UsingPlasmaSystemsinIndustry
3. OverviewofaPlasmaSystem
4. UsingYourPlasmaCutterOperators
Manual
5. OperationofthePlasmaSystem
6. EvaluatingCutQualityand
Troubleshooting

Slide2:CourseObjectives
Uponcompletionofthiscourse,youwillbeable
to:
Demonstrateunderstandingofwhat
plasmaisandhowitworks.
Identifyindustrialusesforplasmasystems.
Compareandcontrastplasmawithother
cuttingmethods,includingoxyfueland
laser.
Identifythepartsofaplasmasystem,
includingconsumables.
Demonstrateunderstandingofplasma
safetyprocedures.
Demonstratetheabilitytoexecute:
o Dropcuts
o Freehandcuts
o Template/guidecuts
o Holepierces
o Gouges
Demonstratetheabilitytoevaluatethe
qualityofcuts.

BevelCut: Thecuttingtechniquethatusesatiltedtorchtoproduceanangleontheedgeof
partsbeingcut.
DropCut: Acutthatresultsinonesectionoftheworkpiecedroppingawayfromthemain
piece.
FreehandCut: Cutsmadewithoutthebenefitofastraightedgeortemplate.
Gouging: Removingmetalfromthesurfaceoftheplatewithoutfullpenetration;usedto
removeoldweldsorprepasurfaceforwelding.
HolePierce: Amethodofstartingacutinwhichthearcplungesintoandthroughthe
workpiecebeforecuttingbegins.
Template/GuideCut: Cutsmadeusingastraightedgeortemplatetoguidethecutalongapredefined
path.

Slide3:CourseEvaluation
Youwillbeevaluatedbasedontwocriteria:
A30questionassessmentbasedonthe
materialscoveredwithinthesixlessons.
Selfandinstructorevaluationsofthecuts
madewiththeplasmasystem.

WhatisaPlasmaSystem
Slide4:WhatisaPlasmaSystem?
Plasmasystemsaremachinesdesignedto
cutvariousthicknessesofelectrically
conductivemetal.
Theyrangefromhandheldportableunits
toautomated,tablemountedunits.
Aplasmasystemuseselectricityandgasto
createaveryhightemperature(20,000C)
arc,alsoknownasplasma.
Theconsumablepartsheldbythetorch
worktoconstrictanddirectthearc,which

maximizesitsefficiencyatcuttingmetal.
Plasmasystemsusethearcandthegas
flowthatshapesthearctomeltmaterial
andblowitawayfromthecutedge,
respectively.

Slide5:WhatArePlasmaSystemsUsedFor?
Plasmasystemscancutanyelectrically
conductivemetal;commonmaterials
includesteel,aluminum,stainlesssteel,
andcopper.
Plasmacuttersaregenerallythefastest
methodforcuttingmaterialsbetween
"(6mm)and2"(62mm)inthickness.
Typicalplasmacutterscancutplateupto
2"(50mm)thick.However,specialized
industrialmachinesareavailabletocut
eventhickermaterials.
Plasmacuttersarealsousedforpiercing,
gouging,andshaping(forexample,bevel
cuts).

Torch Thepartoftheplasmasystemthatisusedtoperformtheactualcutting.
Slide6:TypesofPlasmaSystems
Manualreadilyportableunitsoftenwith
ahandheldtorch,withtypicalcapacityof
cuttingupto2"(5cm)thickplate.Special
straighttorchesallowthesesystemstobe
usedonCNCcuttingtablesforcertain
applications.
Mechanizedtypicallyinstalledina
factorysettingforhighdutycycleuse.
Usuallyoptimizedforveryhighqualityor
highspeedcutting,andsomesystems
capableofcuttingextremelythick
materials.
PlasmaSystemDemonstration

Slide7:SafetyforObservers

ToxicFumesThematerialbeingcutcan
beasourceoftoxicfumesorgasesthat
depleteoxygen.Metalsthatmayrelease
toxicfumesinclude,butarenotlimitedto,
stainlesssteel,carbonsteel,zinc
(galvanized),andcopper.Metalcanalso
becoatedwithsubstancesthatcanrelease
toxicfumes;theymayinclude,butarenot
limitedtolead,cadmium,andberyllium.
PlasmaArcBurnsTheplasmaarcforms
immediatelywhenthetorchswitchis
activatedandwillcutquicklythrough
glovesandskin.Keepclearofthetorchtip
andcuttingpath,andneverpointthe
torchtowardyourselforothers.
EyeandSkinProtectionPlasmaarcrays
produceintensevisibleandinvisible
(ultravioletandinfrared)raysthatcan
burneyesandskin.Useeyeprotection
withappropriatelensshadingandwear
protectiveclothing,includinggauntlet
gloves,safetyshoes,hat,flameretardant
clothing,andcufflesstrouserstoprevent
entryofsparksandslag.Removeany
combustiblesfromyourpocketsbefore
cutting.
PacemakerandHearingAids
Pacemakersandhearingaidoperationcan
beaffectedbymagneticfieldsfromhigh
currents.Wearersofeitherdeviceshould
consultadoctorbeforegoingnearany
plasmaarccuttingandgouging
operations.
WhatisPlasma?

Slide8:PlasmaisaStateofMatter
Engineersusethetermstatetodescribe
thephysicalformofasubstance.Familiar
examplesofstatesaresolid,liquid,or
gas.Undertheproperconditions,every
elementorchemicalcompoundiscapable
ofexistinginthesethreestandardstates.
Whenasubstancechangesstate,the
chemicalmakeupofthesubstance
doesntchange,onlyitsphysicalform
changes.
Changesinstatearealwayscausedby
energyflowingintooroutofasubstance.
Addingheatenergytoasubstancecan
increaseitstemperatureandeventually
causeittochangestate.
Whenheatenergyisaddedtoice,the
temperatureincreases,anditchanges
fromasolid(ice)toaliquid(water).Add
evenmoreheatenergy,andeventuallythe
liquidwillbecomeagas(steam).
Formostsubstances,lowerenergystates
(solids)tendtobemoredenseandrigid
thanhigherenergystates(gases).

Slide9:Whatstateofmatterislightning?

Slide10:Plasmaisthe4thStateofMatter
Thecommoncharacteristicsoflightning
andotherplasmasarethattheyarebright
(radiatinglightenergy)andtheyare
generallyhot(radiatingthermalenergy).
Plasmahasmoreenergythanagasisable
tocontainthemoleculesinplasmaare
breakingdown;theyareexcitedtoapoint
beyondbeingagas.
Thisiswhyplasmaiscalledthe4thState
ofMatter.

Name:
Date:
PlasmaWorksheet
Circletherealworldsubstancesthatcontainplasma.

Stars ElementonElectricStove
PlasmaTelevisions AerosolSprays
LEDs Lightning
Steam FluorescentBulbs
Smoke NeonLights
Auroras StandardLightBulbs
HowisPlasmaCreatedinaPlasmaSystem?
Slide11:HowisPlasmaCreatedinaPlasma
System?
Handheldplasmatorchesreceivegasand
currentflowfromthepowersupply.Theyalso
holdconsumablepartsliketheonesshownhere,
whichhelpshapeandmaintaintheplasmaarc.At
rest,theelectrodeandnozzleareincontact.Gas
blowsbacktheelectrode,creatingaseparation
inthecurrentpath.Electronsflowfromthe
electrodeandcollidewithneutralgasmolecules.
Eachcollisionfreesmoreelectronsandcreates
positivelychargedgasmolecules(ions).A
cascadingcolumnofcollisionsiscreated;this
columnradiatesthermal(orheat)energyandlight
energy(brightness)thisisplasma.Theswirling
gasinsidethetorchpositionsthearcpreciselyin
thecenteroftheelectrodeandpushesitoutof
thenozzle,whereitcanbeusedtocutorgouge
metal.
Aplasmaarccutterconsistsofapowersupplyandatorch.Thepowersupplyisverysimilartoa
battery:itcanprovideaDCelectricalcurrent.Thecarriersofthiselectricalcurrentarecalledelectrons,
andelectronscarryanegativecharge.Theelectronswillflowfromthenegativeterminal,aroundthe
circuit,andbacktothepositiveterminal,formingacircuit.
Therearetwoconsumablepartsconnectedintothecircuit;theyarecalledtheelectrodeandthe
nozzle.Consumablesimplymeansthattheyareslowlydamagedbycontactwiththearcandbythe
heatoftheplasmaarc;theyeventuallywearoutandneedtobereplaced.Otherconsumablepartsona
torchincludetheswirlring,theretainingcap,andtheshield.Theconsumablepartscontrolthesizeand
shapeoftheplasmaarc,andtheycanbeoptimizedforspecificapplicationsortoemphasizeaparticular
attributelikecutspeedorcutquality.Someconsumablesetsareintendedforcuttingthinmetalas
artwork.Theseconsumablesareusedwithminimalstandoffandcutaverynarrowkerf.Other
consumablesareintendedformakingfastcutsinthickermaterialorgouging;thesesetscreatealarger,
widerarc.
Inaplasmaarccutterthetorchisconnectedintothecircuitwiththeelectrodeatthenegativeterminal
andthenozzleatthepositiveterminal.Whentheelectrodeandthenozzleareconductiveandare
touchingeachothercurrentflowsthroughthemunimpeded;weneedtocreateagapinthatcircuitin
ordertomakeanelectricarc.Thepowersupplyofaplasmaarccutterprovidesprocessgas(usually
compressedairforhandheldsystems)tothetorch.Onewayofcreatinganelectricarcinvolvesusing
thepressureoftheprocessgastoseparatetheelectrodeandthenozzlefromeachother.Startinga
plasmaarccuttingtorchbyseparatingashortedelectrodeandnozzletoformanarciscalledcontact
starting,becausetheelectrodeandnozzlestartedincontactwitheachother.
Whentheelectrodeandnozzleseparatewhilealreadyconductingcurrent,theelectrodeemitsastream
ofelectronsfromitshafniumtip.Astheelectronsaccelerateacrossthegap,theycontactneutralgas
moleculeswithenoughforcetostripmoreelectronsfree.Thenthefreeelectronsarereaccelerated
towardthenozzlebytheelectricfieldandthepositiveionsareacceleratedtowardtheelectrode,
makingevenmorecollisionspossible.Thesecollisionscreatemoreandmorepositiveionsandfree
negativeions.
Acascadingcolumnofcollisionsforms;itradiatesthermalenergyandlightenergythisisplasma
resultingintheformationofaspark.Thissparkissimilartothesparkthatiscreatedbypullingthe
toasterplugfromthewallwhenthetoasterisrunning.Thedifferenceisthatthesparkfromthetoaster
plugismomentary,buttheplasmaarcpowersupplyisdesignedtofeedpowertothespark,
instantaneouslyenlargingthesparkintoanarc.Thearcthatformsbetweentheelectrodeandthe
nozzleiscalledthepilotarc.Gasfromthepowersupplyisusedtoforcethepilotarcoutofthenozzle
orifice.
Oncethepilotarchasbeenestablished,theworkpieceneedstobebroughtintothecircuit.The
importantstepisconvertingthepilotarc(betweentheelectrodeandnozzle)intoatransferredarc
betweentheelectrodeandtheworkpiece.Asthetorchapproachestheworkpieceandthepilotarc
contactstheplate,thenozzleandworkpiecestarttosharetheplasmacurrent.Thepowersupplyforces
allthecurrenttogothroughtheworkpiece.Thepowersupplyincreasesthecurrenttothecuttinglevel
andmetalcuttingbegins.
Electrode: Thepartofaconsumablesetthatemitselectronsinasteadystreamtoformtheplasma
arc.
Kerf: Thevoidleftbythelinearremovalofmaterialbyanykindofcuttingprocess;example:
thewidthofthesawbladewhencuttingwood.
Nozzle Aconsumabletorchpartcontainingahole,ororifice,throughwhichthearcpasses.
Hafnium: Themetalusedcommonlyasanelectronemitterforairoroxygenplasmagases.
Slides1216:ReviewandDiscussion
Slide12:Whichwayareelectronsflowing?

Slide13:Howisapilotarcmadeusingthe
contactstartmethod?

Slide14:Whataretworeasonsyoumightchange
consumableparts?

Slide15:Inthecontactstartmethodusedfor
arcformationinPowermaxsystems,whichparts
startincontact?

Slide16:Whatlimitsthelengthofthepilotarc?

HistoryofPlasmaSystems
Slide17:HistoryofPlasmaSystems
Plasmacuttingwasdevelopedinthemid
1950sbyaUnionCarbidedevelopmentengineer
namedBobGage.UnionCarbidehaddevelopeda
heliumTIGweldingtorchcalledHeliarcforwelding
stainlesssteelandexoticalloys.Gageconstrictedthe
weldingarcwithanozzleandincreasedthegasflow.
Bydoingthis,hecreatedenoughgasmomentumand
heatfromthearctocutthroughmaterial.Gagegota
patentforplasmaarccuttingin1957.Originally,
plasmawasusedtocutstainlesssteel,whichcannot
becutwithoxyfuel.Stainlesssteelisaverysmall
subsetofthetotalsteelproductionintheworld;the
vastmajorityiscarbonsteelandalloysteels.Thecutqualityandthereliabilityofthefirstplasma
systemswerepoor,andinthelate50sandearly60stheymetaveryspecificneedforarelativelysmall
market.Mostcustomerswouldonlypurchaseaplasmacuttingsystemoutofnecessity.
Bythelate60s,therewereseveralcompaniesresearchingplasmacutting.Stainlesssteelwasnt
theonlycuttingpossibilityforplasma;italsoofferedasignificantcutspeedadvantageoveroxyfuelon
carbonsteel.Cutqualityoncarbonsteelwasnotgood,butifplasmaeverbecameaviableoptionfor
cuttingcarbonsteelthemarketforplasmawouldmultiplyquickly.Researchersneededtoprovidean
answertothisquestion:whywouldsomeonebuyplasmainsteadofoxyfueltocutcarbonsteel?The
solutionwastofocusresearchonimprovingcutquality.
Oneadvanceledtoanother.Additionofashieldgasimprovedthelifeofconsumableparts.
Switchingthatshieldgastoshieldwatermadeconsumablelifestillbetter.Theuseofwaterpavedthe
wayforwaterinjectionplasmacuttingswirlingtheshieldwaterimprovedcutspeed,cutquality,and
consumablelife.Thoughtherewerestillsignificantchallengeswithdrossformation,itappearedthat
plasmawouldbeanalternativetooxyfuelforcuttingcarbonsteelaswell.
Thenextchallengewastomakeconsistentlyhighqualitycutswithplasma.Evenintothe70s
plasmasystemswereexpensive,unreliable,andspecializedforcuttingstainlesssteel.Consumableparts
lastingmorethan100startswererare.Operatorswerenevercertainwhatwouldhappenwhenthey
pushedthestartbutton.Differencesinmetalcompositiongreatlyaffectedcutquality.Plasmasystem
manufacturersneededtofindacuttingmethodthatworkedwellonallvarietiesofcarbonsteel.
Thesolutionwasoxygenplasmacutting,whichusesoxygentocreateanadditionalchemicalreaction
withcarbonsteel.Cutqualityimproved,andoperatorswereabletoproducecutswithlittleornodross.
Therewasatradeoff,however;oxygenmadeahotterarc,whichusedupconsumablesveryquickly.
Customerslikedthefastercutspeedsandimprovedcutquality,butwerefrustratedwiththelossof
productiontimecausedbyconstantlychangingconsumables.In1983,thatproblemwasaddressedby
waterinjection,whichcooledthenozzleandmadetheconsumableslastlonger.
Slide18:HistoryofPlasmaSystems(cont.)
Sincethe80s,therehavebeenmajoradvances
inplasmacuttingtechnology.Handheldplasma
torchesthatusedairastheplasmagasmadeplasma
availabletoshopsthatdidnothaveaccesstobottled
gases.Shortlythereafter,thestartmechanismfor
handheldplasmasystemswasredesigned,removing
theneedforhighfrequencystarting.Thenewcontact
startdesignallowedforsmallerparts.Reducingthe
sizeandnumberofpartsinthepowersuppliesmade
ahugedifferenceinweight.Bycomparison,a
handheldpowersupplyin1985weighednearly400
pounds;today,therearehandheldsystemsthatonly
weigh20pounds!
25yearsago,somepeoplethoughttherewouldbenomoremajorimprovementstotheplasma
cuttingprocess.Now,over50yearsafteritsinitialdevelopment,weknowthatplasmamanufacturers
arenotclosetoexhaustingthecapabilityofplasma.Whiletherehasnotbeenasignificanttechnological
developmentinthefieldofoxyfuelcuttinginmanyyears,plasmacuttingcontinuestoexpand.Thelast
10yearsalonehaveseenrapidadvancesincutquality,consumablelife,andversatility.Plasmaisnowa
reliable,costeffectivethermalcuttingprocess.Currentresearchisexpectedtofurtherimprovethe
capabilityofplasma.

Dross: Resolidifiedmoltenmetalandoxidesadheringtothetoporbottomedgeofthe
workpieceduringthermalcutting.
WrapUp
Slide19:WrapUpandReviewQuestion
Overview

Name:
Date:
PlasmaCuttingTechnology:TheoryandPractice
Homework#1:WhatisPlasma?
1. Howwouldyoudefineplasma?
2. Namethreeexamplesofplasma.
3. Describehowanarciscreatedinaplasmasystem.
4. Howdoesplasmacut?
Session2:UsingPlasmaSystemsinIndustry
Introduction

Slide0:LessonTitle

Slide1:ReviewQuestions
Hypertherm,Inc|Session2:UsingPlasmaSystemsinIndustry 18
SuitableApplicationsforPlasmaCutting
Slide2:WhatMaterialsandThicknessesareBest
forPlasmaCutting?
Allelectricallyconductivemetalsmost
frequentlycarbonsteel,stainlesssteel,
andaluminum.
Handheldplasmasystemscancutgauge
materialupto2"(50mm)thick,
dependinguponcapacity.
Highamperagemechanizedplasma
systemsarecapableofcuttingmaterials
over6"(15cm)thick.

Plasmacancutthroughdirty,painted,or
rustedmetalswithoutprework
preparationoftheworkpiece(thematerial
beingcut)beforeanycutsaremade.Other
cuttingmethodsofteninvolveprework,but
withplasmaallyouneedisgoodcontactfor
grounding.Typicalmaterialformscutwith
plasmainclude:
Plate
Sheetmetal
Pipe
Expandedmetal(grating)

Slides3and4:TypicalApplications
Cuttingtypicalcuttingthrougha
conductiveworkpiecewithahandheldor
machine(automated)torch:
o Stackcuttingcuttingthrough
severalpiecesofplatestackedon
topofoneanother.
o Templatecuttingcuttinga
workpieceusingashapeor
templateasaguide.
o Bevelingacuttingtechniquethat
producesanangleontheedgeof
thematerialbeingcut(suchasfor
joiningpiecesofpipe).
Piercingstartingacutbyplungingthe
arcintoandthroughtheworkpiece(as
comparedtostartingacutattheedgeof
theworkpiece).
Gougingremovingmetalfromthe
surfaceoftheworkpiecewithoutsevering
thepieceintwo(suchasforweld
preparationorremovinganoldweld).
Markingalowamperageprocess
typicallyusedtowritepartnumbersor
wordsonapartbyremovingathinlayer
oftheworkpiece.
Slide5:IndustriesWhereHandheldPlasma
SystemsareUsed
Somecommonusesformanualplasmasystems
include:
Generalfabrication(pressurevessels,etc.)
andmanufacturingfoodprocessing
equipment,highwayequipment,sign
manufacturing,tankfabrication,andso
on.
Facilityandequipmentmaintenance
railwaymaintenance,sawmill
maintenance,forexample.
Structuralsteelbuildingconstruction
wallandceilingframing,floorandroof
trussfabrication,roofing,siding,and
deckinginstallation.
Shipbuilding.
Containerfabricationandrepair.
Energyoilandgas,offshorerigs,
pipelines.
Vehiclerepairandrestorationbodyand
floorpanelreplacement,exhaustrepair,
framerepair,bracketremoval.
HVAC/mechanicalcontractorsduct
fabricationandalteration,suspension
bracketfabrication.
Agriculturalequipmentrepairremove
rustedpanels,bevelcuts,gougingoutof
oldweldsforreplacements,expanded
metalfabrication.
Ornamentalmetalfabricationfreeform
cutting,piercingandgouging,working
withaluminum,ornamentalfabrication.

Slide6:IndustriesWhereMechanizedPlasma
SystemsareUsed
Somecommonusesformechanizedplasma
systemsinclude:
SteelServiceCenters
JobShops(FabricationShops)
IndustrialManufacturersheavy
equipmentforfarming,agriculture,
construction
Transportationtrailerbodies,railway
cars
VehicleFabricatorspanels,chassisparts
Shipbuilderthickpanels,brackets,
Mining
Energy(Windmills)
Defensenuclear,subs

Slide7:ReviewQuestion#1
Amanufacturerofmedicalequipmentinyour
regionhascalledtoseeifyoucanproduceasetof
50parts,cuttoaspecificshaperequirement.The
platesneedtobe1"(25mm)carbonsteel.How
wouldyoudoit?

Acustomercomesintotheshopandasksifyou
canhelpremovearustedexhaustbracketfroma
vintagetruckthatheisrestoring.Hecangetthe
trucktotheshop,buthesconcernedabout
harmingit,sinceithasconsiderablevalue.How
wouldyoudoit?

Alargeshipbuilderhasaskedyourfirmtobevel17
stainlesssteelpipesinpreparationforweldingtoa
pressurevessel.Howwouldyoudoit?

MechanizedCuttingComparison
Slide10:MechanizedCuttingComparison
Therearethreeprimarytypesofmechanized
plasmacutters:
Oxyfuel
Plasma
Laser

Slide11:Oxyfuel
Oxyfuelcuttersusechemicallygenerated
heattoincreasethetemperatureofthe
workpiece.
Oxygenreactswiththeredhotmetal,
turningitintooxideslag.
Operatorsmustregulategasesforeach
cut.

Slide12:Plasma
Plasmasystemsuseahighenergyplasma
arctocutthroughconductivematerials.
Theconsumablepartsheldbythetorch
worktoconstrictanddirectthearc,which
maximizesitsefficiencyatcuttingmetal.
Plasmasystemsusethearcandthegas
flowthatshapesthearctomeltmaterial
andblowitawayfromthecutedge,
respectively.

Slide13:Laser
Twotypesoflasers,CO2andfiber,are
usedtocutmetal.
Laserstransmitenergyintheformof
coherentphotons.Highintensitylasers
transmitenoughenergytocutnon
reflectivemetal.Fiberlaserscancutsome
reflectivemetalsaswell.
Thematerialmelts,burns,orvaporizes
andisblownawaybyajetofgas,leaving
anedgewithahighqualitysurfacefinish.

Thetightlyfocusedenergyofalasercan
produceverynarrowkerfwidths,
especiallyonthinmaterial.

Slide14:EvaluatingCuttingSolutions
Whentryingtodecidewhatcuttingsolutionto
choose,lookatseveralfactors,including:
CutSpeedHowfastistheactualcutting
process?
CutQualityHowcleanandsquareisthe
finishedcut?Howmuchdrossremains
followingthecut?Isanysecondary
grindingrequired?
PrepWorkHowmuchcleaningandpre
workisneededbeforeamaterialcanbe

cut?
SecondaryWorkWhatisrequiredafter
thecutismadeandhowmuchtimedoes
thattake?
FlexibilityCanthecutteraccommodate
differenttypesofmaterials,typesofcuts,
anddifferentmaterialthicknesses?
MaintenanceHowhardisitto
maintain/repairthesystemandcan
operatorsdoitinhouse?
CostHowmuchdothecutterand
consumablepartscost?

Slide15:EvaluatingCuttingSolutionsLaser
CutSpeed:Veryfastonthinmaterialand
sloweronthickermaterials;longpierce
timesonmaterialsover"(9mm).
CutQuality:Excellentangularity,small
heataffectedzone,virtuallydrossfree,
andexcellentdimensionalaccuracywith
narrowestkerf.
PrepWork:Materialhastobecleanfor
thelasertowork.
SecondaryWork:Littletonone.

Flexibility:Pro:Laserisbestatcuttingthin
carbonsteel.Lasercandocommonline
cuttingthatis,itcanproducefinalcuts
inbothdirectionswithasinglecut.This
reduces/eliminatesskeletons,whichare
thepartsofmetalsheetswhichare
thrownawayafterpartsarecutfrom
them.Con:therearenohandheldlaser
systems,sotheworkpiecemustlieona
tabletobecut.Fiberlasercancutsome
reflectivematerials.Cuttingreflective
material(aluminum)withCO2laser
requirespreworktocoverthematerial
surface.
Maintenance:Complexmaintenancetasks
requirespecializedtechnicians.
Cost:Laserhasthehighestinitialcostof
thethreetherearelasersystemsthat
costover$1M.

Slide16:EvaluatingCuttingSolutionsOxyfuel
CutSpeed:Slowcuttingspeedsacrossa
widerangeofthicknesses(fasterthan
othersystemsoncarbonsteelover2.5"or
62mm);thepreheattimeincreases
piercetimessignificantly,decreasing
overallcuttingspeed.
CutQuality:Goodangularity,largeheat
affectedzone,warpageonthinplate,
drosslevelsrequirerework.
PrepWork:Oxyfuelcuttershaveto
preheattheworkpiecepriortocutting.
Thecutareamustbefreeof
rust/dirt/paintbeforecutting.Operator
mustregulategasflowforeachtorch,and
oxyfueltablesoftenrunmultipletorches
tocompensateforslowercutspeeds.
SecondaryWork:Operatorsmayhaveto
grindofftheheataffectedzone,whichis
largerthanwithothersystems;this
processcanbetimeconsumingand
difficult.
Flexibility:Oxyfuelislimitedtocarbon
steelandisnoteffectiveonstainlesssteel
oraluminum.
Maintenance:Simplemaintenance
requirementscanoftenbeperformedby
inhousemaintenancegroups
Cost:Oxyfuelhasthelowestinitialcostof
thethree.

Slide17:EvaluatingCuttingSolutionsPlasma
CutSpeed:Fastestonawiderangeof
thicknesses,upto2.5"(62mm).
CutQuality:Goodtoexcellentangularity,
smallheataffectedzone,virtuallydross
free,andgoodtoexcellentfinefeature
cutting.
PrepWork:Littletonopreprequired.
Tolerantofpaint/dirt/rust/oilonthework
piece.
SecondaryWork:Littletonogrinding;

typicallylessthanoxyfuel
Flexibility:cutsawiderangeofmaterial
thicknessesandtypes.
Maintenance:Moderatemaintenance
requirements;manycomponentsare
serviceablebyinhousemaintenance
groups.
Cost:Initialcostistypicallybetween
oxyfuelandlaser,rangingfromlessthan
$2,000upto$55,000.

Name:
Date:
ProsandConsActivity
Fillinthechartbelowbyratingeachcuttingtechnologyforeachcriteriawitha1,
2,or3,where1isthebestofthethree,2ismedium,and3istheworst.
Plasma Oxyfuel Laser
CutSpeed
CutQuality
PrepWork
SecondaryWork
Flexibility
Maintenance
InitialCost
Slide19:ProsandConsActivityRecap
Oxyfuelhasalowinitialcost,butislimited
tocarbonsteelandisnoteffectiveon
stainlesssteeloraluminum.
Plasmaprovidesoptimalmixofcutquality,
productivity,andoperatingcost,for
carbonsteel,stainless,andaluminum
acrossawiderangeofthicknessesata
competitivecapitalandequipmentprice.
Laserprovidesexcellentcutqualityand
productivityonthinmaterial.Laser
technologyhashighcapitalequipment,
running,andmaintenancecosts,therefore
ahighlevelofbusinessvolumeisrequired
topaybackthecostoftheequipment.

Cost/BenefitAnalysis

Slide20:StartupCosts
Reviewthestartupcostsassociatedwithplasma
systems:
Plasmasystemsrangeincostfromunder
$2,000forasmallhandheldunittomore
than$55,000forprecisionmechanized
systems.
Startupcostsalsoincludeelectricaland
gashookups.
Inaddition,accessoryequipmentsuchas
tables,ventilation,andmaterialhandling
shouldbefactoredin.Thesecostscanbe
asmuchormorethantheactualsystem,
dependingonthesystemrequirements.

Slide21:CalculatingOperatingCosts
Thetotalcosttooperateanytypeofcutting
equipment(followingtheinitialequipmentcost)is
comprisedoffourprimarycosts,asshownbelow.
Powertoruntheequipment(2%).
Gastoproducetheplasma(4%).
Replacementparts,includingtorch
consumables(6%).
Laborrequiredtooperateandmaintain
theequipment,dorequiredprepwork,
andcompleteanynecessarysecondary
work(88%).
Slide22:LaborCost
Sinceweknowthatlaborisbyfarthelargest
factorincalculatingoperatingcosts,considerthe
featuresofplasmasystemsthatyouthinkmay
helptoreducelabortimerequired.

Slide23:IntroductiontoCaseStudy

Name:
Date:
CaseStudyforCalculatingLaborCosts
TwoshipbuildersinVirginiaBeacharecompetingforacontracttoprovidescheduledmaintenanceona
largecontainership.Onesectionofthejobinvolvesremovingrustedpanelsfromtheshipshulland
replacingthemwithnewpanelscuttofitfrom1"(2.5cm)thicksteelplate.Thereare100panelsonthe
shipthatneedtobereplaced.
ACMEIncorporatedusesareliableoxyfuelcutterthattheyvehadintheshopforyears.Their
laborcostsarecalculatedat$100perhour.Basedonexperience,theyknowthatthefollowing
cuttingtaskswillberequiredtocompletethisjob:
Removetherustedpanels...............................................10minutesperpanel
Cutreplacementpanelsfrom1"(2.5cm)steelplate.....25minutesperpanel
Grindthereplacementpanelspriortowelding..............10minutesperpanel
WeldReplacementPanels...............................................15minutesperpanel

BRAVOIndustriesusesaplasmacutter.Theirlaborcostsarecalculatedat$100perhour.Based
onexperience,theyknowthatthefollowingcuttingtaskswillberequiredtocompletethisjob:
Removetherustedpanels...............................................10minutesperpanel
Cutreplacementpanelsfrom1"(2.5cm)steelplate.......5minutesperpanel
WeldReplacementPanels...............................................15minutesperpanel

Calculatethelaborcostsrequiredtoperformthisjobandthenanswerthefollowingquestions:
1. WhatarethelaborcostsforACMEtoperformthecuttingrequiredbythisjob?

2. WhatarethelaborcostsforBRAVOtoperformthecuttingrequiredbythisjob?

3. Whichcompanydoyouexpectwillgetthejob?

WrapUp
Overview

Name:
Date:
Homework#2:UsingPlasmaSystemsinIndustry
1. Whatmaterialsandthicknessrangecanbecutwithhandheldplasmasystems?
2. Namethreetypicalindustriesforplasmasystems
3. Ifyouneededtocuthighqualitypartsfrom2"(50mm)steelplate,wouldyoubemorelikelyto
chooseahandheldormechanizedplasmasystem?
4. Nameoneproandoneconforeachofthethreeprimarycuttingsystems(plasma,oxyfuel,and
laser)
Session3:OverviewofaPlasmaSystem
Introduction
Slide0:SessionTitle

Hypertherm,Inc|Session3:OverviewofaPlasmaSystem 36
PartsofaPlasmaSystem
Slide2:PartsofaPlasmaSystem
Aplasmasystemwilltypicallyhavethefollowing
components:
Powersupply
Handtorchwithsetofconsumables
Worklead
Itmayalsohavetheseoptionalcomponents,
dependinguponthemanufacturer:
Machinetorch
Extraconsumables

PlasmaCuttingTorchVariations
Slide3:PlasmaCuttingTorchVariations
Shieldedvs.Unshielded
Handheldvs.Mechanized
SingleGasvs.DualGas
Conventionalvs.HighDefinition
Slide4:ShieldedversusUnshielded
Theoriginalplasmacuttingconsumable
setupwasunshielded;gasflowedbetween
theelectrodeandnozzleforminga
plasma.
Thenozzleshapedtheplasmatocut
throughmetal.
Standoffisrequiredwhenusing
unshieldedconsumables.Theoperator
holdsthenozzle1/8"(3mm)offtheplate;
ifthetorchtouchestheplatethe
consumablescanbedamagedorruined.
Someoperatorsuseunshielded
consumablesbecausetheyallowgreater
arcvisibilityintightspaces.
Theshieldservesseveralpurposes:
o Dragtipshieldsallowthetorchto
restdirectlyontheworkbysetting
theproperstandoffdistance.
o Protectstheconsumablesby
keepingthenozzleelectrically
neutral.
o Providessomesecondaryarc
restriction.
Slide5:HandheldversusMechanized
Differentstartingmechanismshandheld
torchesoftenhavecontactstartdesigns,
wheremechanizedtorchesmayuseeither
contactorhighfrequencystarting.
Handtorchesareaircooled;mechanized
torchesmaybewatercooled.

Slide6:SingleGasversusDualGas
Mostsinglegasanddualgastorcheshavea
shieldprotectingthenozzleaswellasa
secondaryflowofgasaroundthenozzle;
thesecondaryflowiscalledshieldgas.
Thedifferencebetweensingleanddualgas
designsissimple:iftheplasmaandshield
gasarethesame,itissinglegas.Ifthey
differ,itisadualgas.
Theselectionofshieldgasdependsonthe
specificcuttingapplication.
Shieldgasserves3purposes:
o Coolsthenozzle.
o Keepsheatfromradiatingbackup
tothenozzle.
o Helpsremovemoltenmaterial.
Inhandheldsystems,theplasmagasand
shieldgasusuallyflowfromasinglesource;
commonly,thegaswillbecompressedair
ornitrogen.Thisisbecause:
o Cutqualityislessimportantthan
withmechanizedsystems.
o Multiplegascylindersandleads
affecttheportabilityofthe
system.
Manygascombinationsareavailable,andare
selectedbasedontheequipmentandthe
specificapplication;gasconsiderationsare
discussedingreaterdetaillaterinthissession.
Slide7:ConventionalPlasmaversusHigh
DefinitionPlasma
AlsocalledPrecisionPlasmaCutting,
highdefinitionisthestateoftheart
mechanizedarcconstrictionmethod.
Highdefinitionprovidesextremely
constrictedplasmaarcsthathave
increasedenergydensity.
o Energydensityisachievedbyhigh
flowvortexnozzles,highvelocity
mixingchambers,magneticfields,
andotherevolvingtechnology.
o Canbesimilartolasercutquality
intermsofangularityanddross.
o Usedonlyinmechanized
applications.

ConsumableSets
Slide8:PlasmaCuttingTorchVariations
Thecommontiebetweenalltorch
variationsistheirconsumableparts.

Slide9:ConsumableSets
Consumablesetsarethepartsinthetorch
thatwearoutovertime.
Howoftenyouneedtochangethe
consumablesdependsonanumberof
factors,including:
o Thicknessandtypeofmaterialbeing
cut.
o Lengthoftheaveragecut.
o Airquality(thepresenceofoil,
moisture,orothercontaminants).
o Whetheryouarepiercingoredge
starting.
o Howwellthepropertorchtowork
distanceismaintainedwith
unshieldedconsumables.
o Properpierceheight.
o Whichconsumablesyouareusing.
ForHyperthermsystems,asetof
consumableslastsapproximately1to2
hoursofactualarcontimeforhandheld
cuttingandasmuchas3to5hoursfor
mechanizedcutting.
Propercareandreplacementoftheseparts
arecriticaltohighquality,economical,safe
cuts.
Alwaysfollowinstructionsfordisconnecting
powerbeforeinspectingorchangingtorch
consumableparts.
Shield(slide10)channelstheflowof
secondarygas,coolsthenozzle,andprotects
theconsumablesfrommoltenspatterand
radiantheat.Thisshieldmaintainstheproper
torchtoworkdistance,whichallowsfordrag
cutting.Thegroovesinthetipoftheshield
allowthegasflowtoblowmoltenmaterial
(andheat)awayfromtheconsumableset.
RetainingCap(slide11)protectsthetorch
frommoltenspatterandradiantheat.Houses
(retains)theelectrode,swirlring,andnozzle.

Nozzle(slide12)constrictsandfocusesthe
plasmagasflow.Typicallythenozzleorificeis
proportionaltoamperage.Thenozzleofa
100Amachinewillhavealargerorificethan
thePowermax45(45A).Alsonotethatthere
arespecialgougingnozzles,whichhavea
largerorifice.Operatorswilllowerthegas
pressure,whichproduceslessconcentrated,
widerplasmaarc.
Electrode(slide13)copperwitha
conductiveinsert(hafnium);theelectrode
carriesthenegativechargefromthepower
supply.Thefinsonthiselectrodearepartof
thestartmechanismgasflowforcesthe
electrodeandnozzletoseparate,allowingfor
arcformation.

SwirlRing(slide14)controlstheflowofgas
intheplasmachamber.Noticethattheholes
intheswirlringareslantedtoswirlthegas
intoavortex(tornado),therebyconcentrating
thegasintoanarrowstream.
Whenassembled,theholesintheswirlring
arebelowthefinsontheelectrode.Whengas
isforcedthroughthoseholes,itpushesagainst
thefinsontheelectrode,forcingitapartfrom
thenozzle.Thismotion,calledblowback,is
whatallowsforarcformationinthe
Powermax45andPowermax65contactstart
method.
BuildingaConsumableSet
Slide15:BuildingaConsumableSet
Itisimportantthatstudentsknowhowto
assembleaconsumablesetforvarious
applications.
Thepartsthatyouchoosewilldependon
thetypeofapplicationandthetypeof
equipmentyouareusing.
Youcanlocatetheconsumable
specificationsinyourOperatorsManual.

Slide16:BuildingaConsumableSet
Workinteamsof3.Onestudentworksin
themanualtoidentifytheappropriate
parts,onestudentassemblestheparts,
andthethirdstudentcheckstheirworkto
makesureitiscorrect.Rotaterolesfor
eachofthethreeactivitiesbelow.
OpenyourPowermax65manualtoSection
3.Thissectionincludestheconsumable
optionsyouwillneedtousetobuildan
appropriateconsumableset.
Youhave34minutestobuildan
appropriateconsumablesetforeachof
thesescenarios.Fillouttheworksheet
(providedonthefollowingpage)foreach
scenario.
Name:
Date:
BuildingaConsumableSet

Application#1:Ametalartistishandcuttinganintricatepatternintothinsheetmetal.Theworking
spaceistightwithsharpangles.Hewantsthebestpossiblecutqualityforhisart.Whatconsumableset
shouldheuse?
ConsumableSet:
Consumables: Part: Number:

Part: Number:
Part: Number:
Part: Number:
Part: Number:

Application#2:Theoperatorispreparingabumpersothatitisreadytobeweldedontoanoldermodel
truck.Hellbegougingthechromeplatedsteel.Whatconsumablesetshouldheuse?
ConsumableSet:

Part: Number:
Part: Number:
Part: Number:
Part: Number:
Application#3:Anoperatorisworkinginaplant,buildingfoodprocessingequipmentonanassembly
line.Thepartsneedtobecreatedquickly,butprecisely,withaPowermax65.Whatconsumableset
shouldheuse?
ConsumableSet:

Part: Number:
Part: Number:
Part: Number:
Part: Number:
GasConsiderations
Slide17:WorkingwithGas
Reviewthefollowingimportantconsiderations
whenworkingwithgasinaplasmasystem:
Clean,dry,oilfreegasisrequired.
Mechanizedplasmaoperatorsusea
varietyofgases;theirchoicedependson
material,thickness,andapplication.
Consulttheoperatormanualtoensure
propergasselection.
Makesuregaslinesarefreeofkinksand
holes.Adropingaspressuremayaffect
cutqualityorcausealossofstart.
Dualflowandhighdefinitionplasma
systemsusetwogases,aplasmagasanda
shieldgas,toprovidebettercutquality
andconsumablelife.Forhandheldplasma,
bothgasesaretypicallycompressedairor
nitrogen.

Slide18:GasOptions
Thetableshowsthefourmostcommongases
usedinplasmasystems,alongwithgeneralpros
andconsforeach.Reviewthechartwiththeclass.

WrapUp
Overview

Name:
Date:
Homework#3:OverviewofaPlasmaSystem
1. Whatisthedifferencebetweensinglegasplasmaanddualflowplasma?
2. Whichplasmacuttingvariationrivalslasercutqualityintermsofangularityanddross?
3. Namethreefactorsthataffectconsumablelife.
4. Howlongcanyouexpectasetofconsumablestolastwhenhandcuttingandwhenmechanized
cutting?Whyaretheydifferent?
5. NamethepartsinaPowermaxconsumableset.
6. Whatisthemostcommonlyusedgasinmanualplasmasystems?
Session4:UsingYourPlasmaSystemOperatorsManual
Introduction
Slide0:TitleSlide

Hypertherm,Inc|Session4:UsingYourPlasmaSystemOperatorsManual 49
ThePlasmaSystemManual
Slide2:ThePlasmaSystemManual
Themanualshouldserveastheoperatorsfirst
resourceforinformationontheplasmasystem.

Slide3:ReferenceManualActivity
UsethePowermax65manualtoansweraseriesof
questions.
Divideinto3groups.Passoutthethree
activityworksheetsonetoeachgroup.
Eachgroupshouldhaveatleastonecopy
ofthePowermax65manual.
Completetheactivitysheets,usingthe
manualandtheSafetyandCompliance
Manualasresourcetools.
Youhave10minutestocompletethe
sheet.

Slide4:ReferenceManualActivity
Reviewyourworksheetswiththeclassbeforewe
moveontothenexttopicsafety.

Name:
Date:
ReferenceManualActivitySheet#1
Youareworkinginanautobodyshopinwhichavarietyofrepairsarerequiredonadailybasis.The
shopjustpurchasedaPowermax65,andtheyintendtouseitforalltypesofhandheldcuts.Youwill
needtosetitupandteachyourcoworkershowtousethemachine.
Answerthesequestionstogetstartedonyourtask.Youllhave10minutestocompletethisworksheet.
Answereachquestioninthespaceprovidedandbesuretoincludethepagenumberinthemanual
whereyoufoundtheinformation.Whenyouarefinished,youwillbeaskedtopresentyouranswersto
thegroup,explaininghowandwhereyoufoundtheinformationwithinthemanual.
Page#
1. Section1:MachineSpecificationsWhattypesofgasinputdoesthePowermax65
take?

2. Section3:TorchSetupChoosetheappropriateshieldedconsumablesforhand
cuttingcarbonsteel.

3. Section5:MaintenanceandRepairWhenyouturnonthecutter,thefaultLED
illuminatesandthefaultcode050displaysontheLCDscreen.Whatdoesthatmean?

4. Section4:OperationThefirstcutyoulltryisapieceof5mmplate.Whereshould
themodeswitchbesetandwhatisthismodecalled?

5. Section3:TorchSetupYoureaskedtoremoveanexistingweld.Whatshieldpart
numberwouldyouuse?

6. Section5:MaintenanceandRepairThearcdoesnttransfertotheworkpiecewhen
youmakeacut.Whatshouldyoudo?

Name:
Date:
YouareworkinginanHVACshop,primarilyfabricatingandalteringductwork.Yourbossjustaskedyou
tolookoveranewPowermax65andbepreparedtoshowyourcoworkershowtousethemachine.
Page#
1. PrefaceHowlongisthewarrantyonthepowersupply?

2. SafetyandComplianceManualForeyeprotection,whatistheminimumprotective
shadenumberforthePowermax45?

3. SafetyandComplianceManualShouldyouturnthepoweroffbeforedisassembling
thetorch?

4. Section1:MachineSpecificationsHowmuchdoesaCSAPowermax65weigh?

5. Section3:TorchSetupWhatistheBestQualitycutspeed(mm/min)forcutting
10mmaluminumwithshieldedconsumables?

6. Section5:MaintenanceandRepairWhenwouldyoureplacetheelectrode?

Name:
Date:
Youareworkingforacustommetalfabricatorthatmakesalltypesofpartstobeusedinmanufacturing.
TheyrecentlypurchasedanewPowermax65plasmasystemandintendtouseitforbothmechanized
andhandcutting.Youwillneedtosetitupandteachyourcoworkershowtousethemachine.
Page#
1. PrefaceHowlongarethefactorysuppliedtorchpartswarranted?

2. Section1:MachineSpecificationsWhatisthemechanizedpiercecapacityofthe
Powermax65?

3. Section4:OperationWhichiseasierwhenhandcuttingpushingthetorchor
pulling/draggingit?

4. Section4:OperationYouareaskedtoremoveanexistingweld.Whatisthe
recommendedangleforgouging?

5. Section4:OperationWhatdoyoudowiththehandclamp?

6. Section5:MaintenanceandRepairThepowerLEDisblinkingandfaultcode013
showsonthescreen.Whatdoesthismean?

SafetyProcedures
Slide5:SafetyProcedureActivity
Thereare9mainsafetytopicscoveredinthe
manual,includingthefollowing:
FireHazards ElectricalShock T
PlasmaArcBurns EyeandSkinProtection G
CompressedGas Noise

Splittheclassintosmallgroupsandassign
eachgrouponesafetytopic.Ifyouhavea
smallclassyoumaywanttocombinetopicsas
follows:
1. FireHazards
2. ElectricalShock
3. ToxicFumes
4. CompressedGas
5. Grounding,Noise,and
Pacemaker/HearingAids
6. PlasmaArcBurnsandEye/Skin
Protection
Take5minutestoreviewthesafety
informationforyourtopic(s)andthenbe
readytopresenttheirfindingstotheclass.

Slide6:FireHazards
Makesurethereisafireextinguisherin
thearea.
Keepallflammablesatleast35feetaway
fromthecuttingarea.

Slide7:ElectricalShock
Touchingliveelectricalpartscancauseafatal
shockorsevereburn.Operatingtheplasma
systemcompletesanelectricalcircuitbetweenthe
torchandtheworkpiece;theworkpieceand
anythingtouchingtheworkpiecearepartofthe
electricalcircuit.
Nevertouchthetorchbody,workpiece,or
thewaterinawatertablewhenthe
plasmasystemisoperating.
Wearinsulatedglovesandboots.

Keepyourbodyandclothingdry.
Hazardousvoltagesandcurrentsattheplasma
tipandINSIDEtheenclosurearesufficienttocause
shock,burnordeath.
Onlytrainedandauthorizedpersonnel
mayopenthisequipment.
Ifpowersourceiscord&plugconnected,
turnoffpowerandunplugpowersource
beforeopeningtheenclosure.
Ifpowersourceispermanentlyconnected,
turnoffandlockout/tagoutpower
beforeopeningenclosure.
Wait5minutesafterremovalofpower
beforeenteringenclosuretoallowstored
energytodischarge.
Ifrequiredtoenergizetheequipmentwith
theenclosureopenforservicing,arcflash
explosionhazardsexist.FollowALLlocal
requirements(e.g.NFPA70EinUSA)for
safeworkpracticesandforPersonal
ProtectiveEquipmentwhenservicing
energizedequipment.
Theenclosureshallbeclosedandthe
properearthgroundcontinuitytothe
enclosureverifiedpriortooperatingthe
equipmentaftermoving,openingor
servicing.
Alwaysfollowtheseinstructionsfor
disconnectingpowerbeforeinspectingor
changingtorchconsumableparts.
Slide8:ToxicFumes
Thematerialbeingcutcanbeasourceoftoxic
fumesorgasesthatdepleteoxygen.Metalsthat
mayreleasetoxicfumesinclude,butarenot
limitedto,stainlesssteel,carbonsteel,zinc
(galvanized),andcopper.Metalcanalsobe
coatedwithsubstancesthatcanreleasetoxic
fumes;theymayinclude,butarenotlimitedto
lead,cadmium,andberyllium.
Toreducetheriskofexposuretofumes:
Removeallcoatingsandsolventsfromthe
metalbeforecutting.
Uselocalexhaustventilationtoremove
fumesfromtheair.
Wearanairsuppliedrespiratorwhen
cuttingmetalcoatedwith,containing,or
suspectedtocontaintoxicelements.
Assurethatoperatorsarequalifiedand
trained.
Nevercutcontainerswithpotentiallytoxic
materialsinside,asthispresents
inhalationandexplosionhazards;empty
andproperlycleanthecontainerfirst.
Monitorortesttheairqualityatthesiteas
needed.
Consultwithalocalexperttoimplementa
siteplantoensuresafeairquality.

Slide9:PlasmaArcBurns
Theplasmaarcformsimmediatelywhenthetorch
switchisactivatedandwillcutquicklythrough
glovesandskin.
Keepclearofthetorchtip.
Donotholdmetalnearthecuttingpath.
Neverpointthetorchtowardyourselfor
others.

Slide10:EyeandSkinProtection
Plasmaarcraysproduceintensevisibleand
invisible(ultravioletandinfrared)raysthatcan
burneyesandskin.
Wearinsulatedglovesandboots.
Weareyeprotection(safetygogglesor
goggleswithsideshields,andawelding
helmet)withappropriatelensshadingto
protecteyesfromthearcsultravioletand
infraredrays.
Wearflameretardantclothingtocoverall
exposedareas.
Wearcufflesstrouserstoprevententryof
sparksandslag.
Removeanycombustibles,suchaslighters
ormatches,frompocketsbeforecutting.

Slide11:Grounding
Attachtheworkcablesecurelytothe
workpieceortheworktablewithgood
metaltometalcontact.
Donotconnectittothepiecethatwillfall
awaywhenthecutiscomplete.
Slide12:CompressedGasEquipment
Useonlygascylinders,regulators,hoses,
andfittingsdesignedforthespecific
application.
Slide13:Noise
Prolongedexposuretohighlevelsofnoisecan
damagehearing.
Ifnecessary,useapprovedearprotection
whenusingaplasmasystem.
Warnothersnearbyaboutthenoise
hazard.
Slide14:PacemakerandHearingAids
Pacemakersandhearingaidoperationcanbe
affectedbymagneticfieldsfromhighcurrents.
Wearersofeitherdeviceshouldconsulta
doctorbeforegoingnearanyplasmaarc
cuttingandgougingoperations.
Slide15:AdditionalSafetyInformation
Additionalsafetyinformationcanbefound
intheresourcesshownonthisslide.

SafetyEquipmentActivity
Slides1629:SafetyEquipmentActivity
WrapUp
Overview
Name:
Date:
Homework#4:UsingaPlasmaSystemSafely
1. Namethreethingsyoucanlearnfromthemanual.
2. Howdoyoudeterminewhatconsumablestouseinaplasmasystem?
3. Whatistheworkclampusedfor?
4. Whenhandcutting,isiteasiertopushorpullthetorch?
5. Whichconsumablepartsshouldbereplacedmostfrequently?
6. Namethreepiecesofprotectiveclothingthatyoushouldwearwhenoperatingaplasmasystem.
7. Howlongdoesittakeforthearctoformwhentheplasmasystemtorchtriggerswitchis
activated?
8. Areairsuppliedrespiratorsneededeverytimeyouuseaplasmasystem?
Session5:OperationofthePlasmaSystem
Introduction
Slide0:TitleSlide
Hypertherm,Inc|Session5:OperationofthePlasmaSystem 61
CommonTerminology
Slide2:CommonTerminologyReview
MachineStartUp
Slide14:MachineStartUp
Asummaryoftheinformationpresentedwithinthe
videoisprovidedonthefollowingpages.
Verifythepowerisdisconnectedand,ifcord&plug
typepowersource,verifythepowerplugisunplugged
priortoStep1.
Step1:Checktheproperinstallationofthetorch
consumables
Unscrewtheretainingcaptoremovetheparts
within.
Replacethepartsbyfirstinsertingthenozzle,thentheelectrode,followedbytheswirlring.
Screwtheretainingcaponuntilfingertight;donotovertightenastheconsumablesmay
becomedamaged.
Step2:Connectthetorchleadtothefrontofthepowersupply
Step3:Connectthegas
Pullbackthequickreleasecollaronthegashoseandinsertonthequickdisconnectfitting.
Thegascanbeeitherbottlednitrogen,bottledair,orcompressedair.
Airshouldbefilteredtoremovealldirt,water,andoilbecausecontaminantscandamagethe
powersupply,torch,andconsumables.
Minimumgaspressure:80psior5.5bar.
Maximumgaspressure:100psior6.9bar.
Step4:Attachtheworkclamp
Checktoseethattheworkleadisattachedtothepowersupply.(Somesystemsdonothavea
quickdisconnectontheworklead.)ForthePowermax6,pushtheconnectorintothereceptable
andturnclockwiseturn,makingsurethattheconnectorisfullyseatedagainstthestopto
achieveanoptimalelectricalconnection.
Attachtheworkclampsecurelytotheworkpieceorthecuttingtablenearthecut.
Rust,paint,orcoatingsmustberemovedtobesurethattheclamphasagoodelectricalcontact.
Theclampshouldneverbeattachedtotheportionofthemetalthatwillfallaway.
Step5:Poweronthesystem
Plugthepowercordintotheproperreceptacle.
Poweronthesystem.
Thepowerlamponthefrontofthesystemwillilluminate.
Forinputvoltagerequirements,lookatthedataplateonthebottomorbackofthepower
supplyorintheoperatormanual.
Step6:Setthemodeswitch
Settheswitchtoplatecutting.Thepositionmayvary.OnthePowermax45,forexample,itisthe
middleposition.OnthePowermax65,itisthesecondposition.
Step7:Checkthegaspressure
SystemssuchasthePowermax65mayhaveautomaticgasadjustment.Unlessthereisafault
lightilluminatedandagaspressurefaultcodeontheLEDscreen,thegaspressureiscorrect.
Othersystems,likethePowermax45,mayrequirethatyouadjustthepressure:
o IftheLEDbarinthepressuregaugeisgreen,thegaspressureissetcorrectly.
o IftheLEDisyellow,thegaspressureneedsadjustment.
o Toadjustthegaspressure,turntheamperageknoballofthewaycounterclockwiseto
thegastestposition.
o Then,pulltheregulatorknobtounlockit.
o TurntheknobuntilthegreenLEDappearsinthecenterofthepressurebar.
o Then,pushtheregulatorknobtolockit.
Step8:Adjusttheamperage
Adjusttheamperageknobtothetopamperagesettingforfullcuttingpower(65ampsforthe
Powermax65).
Ifcuttingthinnermetal,theamperagemaybeloweredforimprovedconsumablelifeandcut
quality.
Step9:Operatethesafetytrigger
Avoidunnecessarystarts,becausetheyreducethenozzleandelectrodelife.
PerforminganEdgeStartandDropCut
Holdthetorchvertically(perpendiculartoworkpiece),justofftheedgeoftheworkpiece.
Theshieldmaybeplacedontheworkpieceforeaseofcutting.
Flipthesafetytriggerforwardandpresstheredtorchtrigger.
Thepilotarctransferstotheworkpieceandbecomesthecuttingarc.
Pauseattheedge,allowingthearctocutcompletelythroughtheworkpiecebeforeproceeding
withthecut.
Pulltorchsteadilytocut.
Whennearingtheendofthecut,rollyourtorchhandforwardslightly,liftingyourwrist.Thiswill
anglethetorchintothedirectionofthecut,allowingthearctocompletelyseverthematerial.
ProperTravelSpeed
Maintainingpropertravelspeediskeytosuccessfulcutting.
Watchthearcbeneaththeplate;sparksshouldlag15to30degreesbehindthecut.
Ifthesparksarevertical,thenthespeedistooslow.
Ifthesparksareperpendiculartothecutoraresprayingupfromtheworkpiece,thenthespeed
istoofastorthesystemdoesnothavesufficientpower.Laglinesonthefinishedcutedge
shouldalsobeabout15to30.
TemplateCutting
Aplasmacuttingguide,straightedge,ortemplatecanbeusedtoguidethetorch.
Thedistancefromtheshieldscentertotheedgemustbefactoredinwhencreatingatemplate
orplacingthestraightedge.
BevelCuts
Ifyouarebevelingusingaplasmacuttingguideorfreehand,rememberthatthematerial
thicknessincreasesproportionallywiththebevelangle.
Piercing
Thepiercingcapabilityofthesystemisroughlyhalfofthemaximumcutcapacity
Dependingonthethicknessofthemetalbeingpiercedandthesystembeingused,thereare
twomethodsofpiercing:
o Ifpiercingthinmetal,holdthetorchperpendiculartotheworkpieceandpullthetrigger
totransferthearc.
o Ifpiercingthickmetal,holdthetorchata45anglesothatthenozzleiswithin1/8"
(3mm)fromtheworkpiece;pullthetriggertotransferthearc,thenslowlyrotateitto
anuprightposition.
Inbothmethods,whensparksareexitingfromthebottomoftheworkpiecethemetalhasbeen
piercedandthencuttingcanbegin.
Toprolongthelifeoftheconsumables,itisrecommendedthatthesecondmethodbeusedto
minimizedamagetotheconsumablescausedbymoltenmetalblowback.
CuttingExpandedMetal
Tocutexpandedmetal(grating),oranapplicationwithinterruptedcuts,setthemodeswitchto
ExpandedMetalCutting,whichisthetopposition.
Thisenablesthesystemtoautomaticallyreinitiatethepilotarcwithoutretriggering.
Tocut,simplyfollowthesameproceduresasoutlinedforplatecutting.
Gouging
Togouge,firstturnoffthesystem,installthegougingconsumables,thenrestartthesystem.
Setthemodeswitchtogouging.OnthePowermax45,thisisthebottomposition.Onthe
Powermax65,itisthethirdposition.
Dependingonthesystemyouareusing,youmayneedtoadjustthegaspressuretogetawider,
diffusedarcforgouging.ThePowermax65doesthisforyou.IfyouareusingaPowermax45or
othernonautogassystem:
o Turnthecurrentknoballofthewaycounterclockwisetothegastestposition.
o Thenpulltheregulatorknobtounlockit,turntheknobuntilthegreenLEDappearsin
thecenterofthepressurebar,andpushtheknobbackdowntolockit.
Adjusttheamperagetofulloutputforfullgougingpower.
Holdthetorchatapproximatelya45anglefromtheworkpiece,withasmallgapbetweenthe
torchtipandtheworkpiece,thenpullthetriggertotransferthearc.
Maintainthisangleandslowlymovethetorchalongtheworkpiecetoremoveunwantedmetal
orweld.
Ifashallowergougeisdesired,decreasetheangleofthetorch.
Foradeepergouge,increasetheangleofthetorchormakeadditionalpasses.
SystemOptimization
Cutqualityandconsumablelifearetwoveryimportantfactorsforoperators.
Toensurethatthetorchconsumableslastaslongastheyaredesignedtolastandperformto
manufacturersspecifications,followtheinstructionsinthisvideo,refertothesuppliedcut
chartsforpropersetup,andfollowpropermaintenanceprocedures.
Anumberoffactorsdeterminehowlongconsumableslast,includingairquality,piercing
technique,lengthofaveragecut,operatorskill,materialthickness,andmaterialtype.
Reducedsystemperformanceandcutqualityareoftencausedbypoorairquality,sobesureto
maintainclean,dry,oilfreeair.
Accessories
Manufacturersofferavarietyofaccessories,including:
Airfilters
Plasmacuttingguides
Leathertorchsheathing
Systemdustcovers
Faceshields
Gloves
ExecuteaDropCut
Purpose: Buildconfidencewithfreehandplasmacuttingbyexperimentingwithtechnique,cutspeed
changes,torchanglechanges,etc.Also,reviewandpracticemachinesetupandproperuse
ofPPE.
Time: 2530minutes
Materials:
1. Plasmasystemwithallnecessaryhookups(air,power,ground).
2. Protectiveeyewearforeveryoneinclass.
3. AtleastonecompletesetofPPE(preferably2+).
4. CopyoftheappropriateQuickSetUpGuide.
5. Enoughcarbonsteelfor50+straightcuts[recommended:atleast3feet(90cm)x1foot(30
cm)].

Directions:
Bringsystemtocuttingareaoftheworkshop.
MimictheMachineStartupactivity;studentstaketurnsusingtheQuickSetUpGuideto
preparetheplasmasystemforcutting.
Reviewdropcuttechniqueforgroup,demonstratingcutspeedandtorchangleWITHOUT
actuallycuttingleavethefunpartforyourclassthistime!
FirststudentputsonfullPPEandchecksthatsystemisreadyforcutting.
Checkthateveryonehasprotectiveeyewearonbeforecuttingbegins.Remindclassabout
safetyasobservers(distancefromsparks,keepeyeprotectiononfordurationofcut,andso
on.)
Eachstudentwillgettheopportunitytoperform23dropcuts.
Classobservesthestudentcuttingtoprovideconstructivefeedback.
Aftereachcut,stopandreviewtechniquewithentireclass.
WrapUp
Overview

Name:
Date:
Homework#5:OperationofthePlasmaSystem
1. Isitnecessarytochecktheproperinstallationofthetorchconsumableseverytimeyoustartup
thesystem?Whyorwhynot?
2. Whyisitimportanttohavethepropergaspressure?
3. Whatistheresolidifiedmoltenmetalthatadherestothecutedgecalled?
4. Whattypeofcutisusedtoproduceanangleontheedge?
5. Whatisthevoidleftbetweentwocutpartscalled?
6. Whatisacutcalledthatismadebyhand,withoutthebenefitofastraightedgeortemplate?
7. Whatisitcalledwhenyouusetheplasmasystemtoremovemetalfromthesurfaceoftheplate
withoutseveringtheworkpiece?
Session6:EvaluatingCutQualityandTroubleshooting
Introduction
Slide0:TitleSlide

Hypertherm,Inc|Session6:EvaluatingCutQualityandTroubleshooting 74
PrimaryFactorsAffectingCutQuality
Slide2:EvaluatingCutQuality
Therearethreeprimaryfactorstoconsiderwhen
assessingcutquality:
Drossthemoltenmaterialthatsolidifies
onthetoporbottomoftheworkpiece.
CutAnglethedegreeofangularityofthe
cutedge.
CutSurfacethecutsurfacecanbe
concaveorconvex,andmayhavevarying
surfacefinish(bothintermsof
straightnessandtexture);handheld
plasmacuttingtypicallyproducesa
roughercutsurfacethanmechanized
plasma.
Slide3:Dross
Drossisresolidifiedmoltenmetaland
oxidesthatadheretothetoporbottom
edgeduringthermalcutting.
Someamountofdrosswillalwaysbe
presentwhencuttingwithairplasma.
Excessivedrossisprimarilycausedwhen
thetravelspeedistoofastortooslowfor
thematerialbeingcut.
Slide4:AppropriateTravelSpeed
Whenyouarecuttingatthecorrectspeed,
thesparksshouldappearfromthebottom
ofyourcutandlagslightlybehindthe
torchata15to30anglefromvertical;
thisishardtoseeforyourselfyoumay
wanttohavesomeonewatchandprovide
feedbackasyoucut.
Ifsparkssprayup,thetorchismovingtoo
fast;thisissometimescalledarooster
tail.
Ifsparksappearclosertoverticalfromthe
bottomofthecut,thetorchismovingtoo
slow.
Slide5:AppropriateTravelSpeed(cont.)
Thelaglinesontheedgeofthecutshow
whetheryourspeedwasappropriate;the
lineslooklikeanscurveonthecut.
Howtomeasurealaglineangle:
o Pickaspotroughlyinthemiddleof
yourcut.Drawastraightverticalline.
Thiswillbeyourreferenceline.
o Next,findthelaglinethatbeginsat
thetopofyourverticalline.Drawa
straightlinefromthebeginningtothe
endofthelagline.
o Useaprotractortomeasuretheangle.
Yourlaglinesshouldbeapproximately
15to30fromvertical.
Slide6:MinimizingLowSpeedDross
Lowspeeddrossformswhenthetorchs
cuttingspeedistooslowandthearc
shootsahead.
Itistypicallyaheavy,bubblydepositatthe
bottomofthecutandcanberemoved
easily.
Ifthishappens,increasecuttingspeed.
Slide7:MinimizingHighSpeedDross
Highspeeddrossformswhenthetorchs
cuttingspeedistoofastandthearclags
behind.
Drossformsasathin,linearbeadofsolid
metalveryclosetothecut;itisweldedto
thebottomofthecutandisdifficultto
remove.
Ifthishappens,decreasecuttingspeedor
decreasethetorchtoworkdistance.

Slide8:NotesaboutDross
Drossismorelikelytoformonwarmor
hotmetalthanoncoolmetal.Therefore,
thefirstcutinaseriesofcutsusually
producestheleastdross.Asthe
workpieceheatsup,moredrossmayform
onsubsequentcuts.
Drossismorelikelytoformoncarbon
steelthanonstainlesssteeloraluminum.
Wornordamagedconsumablesmay
producedross.

Slide9:CutorBevelAngle
Youwantthecutsthatyoumaketobe
square,whichmeansthatthereisno
bevelonthesidesofthecut.
Wehavementionedseveraltimesthat
thedragshieldallowsyoutodragthe
torchalongthesurfaceoftheworkpiece,
keepingthearcattheproperdistance
fromtheworkpiecehereisanother
illustrationofhowthatworks:itmakes
surethearcshapethatdoesthecuttingis
asclosetosquareaspossible.
Thearcitselfhasanangleasshowninthe
slide.
Apositivecutangle(orbevel)resultswhen
morematerialisremovedfromthetopof
thecutthanfromthebottom.
Anegativecutangleresultswhenmore
materialisremovedfromthebottomof
thecut.
Notethatthehighestqualitycutsare
alwaysontherightwithrespecttothe
forwardmotionofthetorchthisis
becausethearcswirlsclockwise(when
viewedfromoverhead),soitisactually
hottestandthemostdensewhereitexits
therightcutedge.
Slide10:StraightnessoftheCutSurface
Thetypicalplasmacutsurfaceisslightly
concaveandthisistheshapethatyou
want.
Slide11:StronglyConcaveCutSurface
Astronglyconcavecutsurfaceoccurs
whenthetorchtoworkdistanceistoo
low.
Increasethetorchtoworkdistanceto
straightenthecutsurface,
Slide12:StronglyConvexCutSurface
Astronglyconvexcutsurfaceoccurswhen
thetorchtoworkdistanceistoogreator
thecuttingcurrentistoohigh.
Evaluating Cut Quality Activity

Purpose: Familiarizestudentswiththemeasurementtoolsusedtodeterminerelativecutquality,as
wellasmethodsofoptimization.Studentswillbecomemorecomfortablewithself
assessmentandwillbecomefamiliarwithhowtorecommendadjustments
Time: 1520minutes
Materials: 1. CutEvaluationWorksheetincludesdefinitionsofcutassessmentterminology.
2. StudentcutsfromSession5.
Directions:
GatherthestudentscutsfromSession5andlookatthemasagroup.
Pickthreeorfourcutsthatshowexamplesofvariationssuchashighorlowspeeddross,good
orbadcutangles,and/orconvexorconcavecutsurfaces.
Eachstudentwillhaveacutevaluationworksheettoevaluateeachcutbasedonwhatwas
learnedwithinthislesson.
Whenyouarefinished,discusseachcutasagrouptoprovidefeedbackandreinforcementfor
studentselections.

Name:
Date:
Cut:
EvaluatingCutQuality
1. Drossthemoltenmaterialthatsolidifiesonthetoporbottomoftheworkpiece
LowSpeedDross DrossFree HighSpeedDross

| | | | | | | | |
Whatwouldyoudotoimprovethedrossbuildupontheworkpiece?
2. CutAnglethedegreeofangularityofthecutedge
NegativeCutAngle SquareCut PositiveCutAngle

| | | | | | | | |
Whatwouldyoudotoimprovethecutangle?
3. StraightnessoftheCutSurfacethecutsurfacecanbeconcaveorconvex
Concave Straight Convex

| | | | | | | | |
Whatwouldyoudotoimprovethestraightnessofthecutsurface?
OtherTroubleshootingTips
Slide13:Ipulledthetrigger,butitwontfire
Aplasmatorchisdesignedtoinitiateanarcby
runningacurrentthroughtheelectrodeand
nozzle,whicharetouchingwhenthetorchisidle.
Whenthetriggerispulledwhilecurrentisflowing,
thegasflowpushesthetwopiecesapartand
producestheinitialplasma.Withoutthis
separationorinitialarc,acuttingarcwillnotform.
Possiblesolutionsinclude:
Loosentheretainingcapandtryagain
thismayfreeuptheelectrodesoitcan
separatefromthenozzlewiththegas
flow.
Checktheconsumablepartnumbers
againstthestickeronthetopofthe
machineifpartsaremismatchedorin
thewrongorder,theymaynotbemaking
contactormaynotbeabletoseparate
whenthetriggerispulled.
Tryanothertorch,ifpossibleputtinga
workingtorchonthesystemwillquickly
determinewhethertheproblemisinthe
torchorthepowersupply.

Slide14:Itlosesthearcduringthecut
Ifthishappensonlyoccasionally,itmaybedueto
marginalpoweroracontaminatedairsupply.Ifit
happensalwaysorifsubstitutingaworkingtorch
doesntsolvetheproblem,thenitneedstogo
backtothemanufacturerforrepair.
Todiagnosetheproblem:
WatchforafaultLEDorfaultcodetoflash
onifthepowerorgassupplyismarginal,
itspossiblethateitherwillbedrawnlow
duringacut.
Tryanothertorch,ifpossibleiftheresa
faultyswitchinthetorchorabroken
conductorintheleadsetusersmay
experiencethisproblemastheymovethe
torcharoundduringthecut.
Slide15:TheresaninterlockLEDon
First,checktheOperationsectionofthe
manual;theLEDshaveslightdifferences
fromonemachinetothenext.Themanual
shouldhelpsolvetheproblem.
IfyouseethelightningboltLED(whichcan
beredoryellow),twocommonreasons
are:
o Theretainingcapistootight
loosenitslightlytosolvethe
problem.

o Theplungerhasbecomefouled
andisntreturningtheelectrode
toitsidleposition(thismayalso
causepittingoftheplunger).

Slide16:Imusinglotsofconsumables
Consumablelifedependsonmanyvariables,
includingamperage(moreamps=shorter
consumablelife),materialthickness(greater
thickness=shorterlife),feedrate(fastercuts=
shorterlife),andpiercing(edgestartinghelps
preserveconsumables).
Sometipsforassessingandextendingthelifeof
yourconsumablesinclude:
Whatkindoflifeareyougetting?Expect1
to2hoursofarctimeformanualcutting.
Usingdragtip?Keepthetorchonthe
material.
Eliminateanymoistureintheincomingair
supply.

Slide17:Itdoesntcutlikeitusedto
Cutqualityisgreatlyinfluencedbytheusers
technique.Therefore,thefirststepistoassess
howthecutqualityhaschanged(ifatall).
Sometipsforassessingandimprovingcutquality
include:
Assesshowcutqualityaschanged.
Especiallywithhandheldplasma,some
minorangularityanddrossisexpected.
Replacetheconsumables.Trythenozzle
andelectrodefirst,andthentheswirlring.

Eliminateanymoistureintheincomingair
supply.
Changeinthecompositionofthe
workpiececanaffectcutquality.

Name:
Date:
TroubleshootingActivity
Matchtheproblemwiththemostlikelycausebywritingtheappropriateletterintheblanksontheleft.
Problem MostLikelyCause
___ ConvexCutSurface A. Cuttingspeedtoofast
____ Arcwontfirewhen
B. Torchtoworkdistanceistoolow
thetriggerispulled
____ Thin,lineardrossformation
C. Cuttingspeedtooslow
onthebottomofthecut
____ Positivecutangle D.Powerorgassupplyismarginal
____Negativecutangle E. Mismatchedconsumables
____ Heavy,bubblydross
depositatbottomofthe F. Torchtoworkdistanceistoohigh
cut
____ Torchlosesthearcduring G.Ifusingadragtip,keepthetorchon

cutting theworkplate
I. Torchtoworkdistanceistoogreat
____ Shortconsumablelife
orcuttingcurrentistoohigh
WrapUp
Overview
Name:
Date:
Homework#6:EvaluatingCutQuality
1. Namethethreecriteriathatareusedtoevaluatecutquality.
2. Whatisthebestwaytoreducetheamountofdrossformationwhencuttingwithaplasma
system?
3. Whenyouarecuttingattheappropriatespeed,whatshouldthesparksgeneratedbythe
plasmasystemlooklike?
4. Whatisthenameforathin,linearbeadofsolidmetalveryclosetothecutwhichisweldedto
thebottomofthecutandisdifficulttoremove?Whatadjustmentcanbemadetoreducethis
formation?
5. Whichsideofthecuthasthehighestqualityandwhy?
6. Ifthearcwontfirewhenthetriggerispulled,whatisthemostlikelyproblem?
7. Onaverage,howlongcanyouexpectasetofconsumablesinahandheldsystemtolast?
Glossary
BevelCut Thecuttingtechniquethatusesatiltedtorchtoproduceanangleontheedgeofparts
beingcut.
DropCut Acutthatresultsinonesectionoftheworkpiecedroppingawayfromthemainpiece.
Dross Resolidifiedmoltenmetalandoxidesadheringtothetoporbottomedgeofthe
workpieceduringthermalcutting.
Electrode Thepartofaconsumablesetthatemitselectronsinasteadystreamtoformtheplasma
arc.
FreehandCut Cutsmadewithoutthebenefitofastraightedgeortemplate.
Gouging Removingmetalfromthesurfaceoftheplatewithoutfullpenetration;usedtoremove
oldweldsorprepareasurfaceforwelding.
GuideCut Cutsmadeusingastraightedgeortemplatetoguidethecutalongapredefinedpath.
Hafnium Themetalusedcommonlyasanelectronemitterforairoroxygenplasmagases.
HolePierce Amethodofstartingacutinwhichthearcplungesintoandthroughtheworkpiece
beforecuttingbegins.
Kerf Thevoidleftbythelinearremovalofmaterialbyanykindofcuttingprocess;example:
thewidthofthesawbladewhencuttingwood.
Nozzle Aconsumabletorchpartcontainingahole,ororifice,throughwhichthearcpasses.
TemplateCut Cutsmadeusingastraightedgeortemplatetoguidethecutalongapredefinedpath.
Torch Thepartoftheplasmasystemthatisusedtoperformtheactualcutting.
Hypertherm,Inc|Glossary 87

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Introduction

Plasma Oxyfuel Laser

Consumables: Part: Number:

Consumables: Part: Number:

Consumables: Part: Number:

Evaluating Cut Quality Activity

LowSpeedDross DrossFree HighSpeedDross

NegativeCutAngle SquareCut PositiveCutAngle

Concave Straight Convex

___ ConvexCutSurface A. Cuttingspeedtoofast

____ Positivecutangle D.Powerorgassupplyismarginal

____ Torchlosesthearcduring G.Ifusingadragtip,keepthetorchon

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