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
No

distortion from heat

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
Do

electrode into anti-spatter compound

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
1/16
1/8
1/4
1/4
3/8
3/8
1/2
1/2

Current
35 amps
40 amps
40 amps
80 amps
40 amps
80 amps
40 amps
80 amps

Travel Speed
175 in/min
90 in/min
40 in/min
100 in/min
18 in/min
55 in/min
20 in/min
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
Thickness
of Metal
in Inches
Light gauge
to 3/16
3/16 - 3/8
3/8 - 5/8
5/8-1
1-2
2-3
3-6

CUTTING TIP SELECTION CHART

Tip
Cutting Oxygen Acetylene Oxygen
Acetylene
Size
Orifice Pressure Pressure Consumption Consumption
Number Drill Size (P.S.I.G.) (P.S.I.G.) (SCFH)
(SCFH)
000
00
0
1
2
3
4

#68
#64
#60
#56
#52
#48
#42

15-20
20-25
35-40
35-40
40-45
45-50
50-75

5-15
5-15
5-15
5-15
5-15
5-15
10-15

35-40
45-50
75-85
97-107
180-195
270-290
450-600

10-15
10-15
15-20
15-20
20-30
20-35
25-40

Oxy-Fuel Cutting Set-up

All

set 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