Basic tips to improve plasma cut quality on metal https://www.hypertherm.com/learn/articles/basic-tips-to-improve-plas...

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Informational Posted on 31/03/2016

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The following reference guide offers several solutions Plasma cutting (/learn
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to help improve cut quality on metal. It is important to /articles
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try and work through the suggestions provided – as /?tag=Plasma+cutting),
(6)
often there are many different factors to consider: Preventive maintenance
Consumables
(/learn/articles
(/learn/articles Type of machine (e.g. X-Y table, punch press, /?tag=Preventive+maintenance
/?type=Articles& motorized track, robot)
tag=Consumables) Plasma cutting system (e.g. air plasma system, Posted on 05/01/2018

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Basic tips to improve plasma cut quality on metal https://www.hypertherm.com/learn/articles/basic-tips-to-improve-plas...

(5) oxygen plasma, high definition class plasma)

Fabrication (/learn Motion control device (e.g. capability of the CNC
/articles machine and torch height control)
/?type=Articles& Process variables (e.g. cutting speed, cut height,
tag=Fabrication) choice of consumables)
(5) External variables (e.g. material variability, gas
(https://www.hypertherm.com
Powermax45 purity, operator experience)
/learn/case-studies/weld-
plasma system
It is important to consider all of these factors when preparation/)
(/learn/articles
attempting to improve the appearance of a cut.
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tag=Powermax45+plasma+system)
(5)
Gouging (/learn (/learn/case-studies
/articles /weld-preparation/)
/?type=Articles& Case studies (/learn
tag=Gouging) (3) /case-studies
More tags + /?type=Case+studies),
The squarest cut angles are always to the right side,
with respect to the forward motion of the torch. Customer story (/learn
/case-studies
Check direction of the cut /?cat=Customer+story),
Adjust the cutting direction, if needed HyAccess extended
consumables for
All mo… The plasma arc typically spins clockwise with standard
consumables. Powermax systems
(/learn/case-studies
Contour: /?tag=HyAccess+extended+consuma
Torch travels clockwise Powermax125 plasma
system (/learn/case-
Good side of the cut is to the right side of the torch,
Articles as it travels forward studies
/?tag=Powermax125+plasma+system
(/learn
Posted on 29/03/2016
/articles/)

Internal feature (hole):

Torch travels counter-clockwise

Good side of the cut is to the right side of the torch,
as it travels forward.

Plate with internal hole

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Basic tips to improve plasma cut quality on metal https://www.hypertherm.com/learn/articles/basic-tips-to-improve-plas...

Refer to the cut charts in the Operation section of the

Hypertherm Instruction Manual.

Be sure to follow the specifications in the cut charts:

Select the appropriate process for:

Metal type
Metal thickness
Desired cut quality
Productivity goals
Select correct plasma and shield gas if using a dual-
gas plasma cutting system
Select correct parameters for:

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Basic tips to improve plasma cut quality on metal https://www.hypertherm.com/learn/articles/basic-tips-to-improve-plas...

Gas pressures (or flow rates)

Torch-to-work distance and arc voltage
Cutting speed
Confirm the correct consumables (tips) are being
used and verify the part numbers

Note: Generally, lower amperage processes offer better

angularity and surface finish; however, cutting speeds
will be slower and dross levels will be higher.

Inspect consumables for wear

Replace worn consumables
Always replace the nozzle and electrode at the
same time
Avoid over-lubricating o-rings

Note: Use genuine Hypertherm consumables to ensure

maximum cutting performance.

Level the workpiece

Square the torch to the workpiece (both from the
front and side of the torch)

Note: Check to see if material is bent or warped; in

extreme cases this limitation cannot be corrected.

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Basic tips to improve plasma cut quality on metal https://www.hypertherm.com/learn/articles/basic-tips-to-improve-plas...

Adjust torch-to-work distance to the correct setting

If using arc voltage control, adjust voltage

Note: As consumable parts wear, arc voltage settings

need continual adjustment to maintain torch-to-work
distance.

Torch-to-work distance can impact angularity

Negative cut angle: torch too low; increase torch-

to-work distance
Positive cut angle: torch too high; decrease torch-
to-work distance

Note: A slight variation in cut angles may be normal,

as long as it is within tolerance.

Adjust cutting speed, as needed

Note: Cutting speed may also impact your dross levels.

High-speed dross: Cutting speed too fast (arc lags

behind), reduce cutting speed
Low-speed dross: Cutting speed too slow (arc
shoots ahead), increase cutting speed
Top spatter: Cutting speed too fast, reduce cutting
speed

Note: In addition to speed, both material chemistry

and surface finish can impact dross levels; as
workpiece heats up, more dross may form on
subsequent cuts.

Identify and repair any leaks or restrictions

Use properly sized regulators and gas lines
Use pure, high-quality gas
If manual purge required, such as with the MAX200,
confirm purging cycle was completed
Consult the gas distributor

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Basic tips to improve plasma cut quality on metal https://www.hypertherm.com/learn/articles/basic-tips-to-improve-plas...

Make sure that the torch is secure to the table

gantry
Consult OEM; table may require maintenance

Check and ensure that the table is cutting at

specified speed
Consult OEM; table speed may need tuning

Posted on 31/03/2016
Posted by Hypertherm

Articles (/learn/articles/?type=Articles), Tips and

techniques (/learn/articles/?cat=Tips+and+techniques),
Cut quality (/learn/articles/?tag=Cut+quality), Dross
(/learn/articles/?tag=Dross)

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