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Nozzle size also has a direct affect on kerf width since the nozzle orifice constricts the plasma gas jet to a particular diameter. The plasma arc is dynamic (it changes in size and shape depending on amperage, voltage, gas flow and velocity of the moving torch) and so as the plasma arc column changes so does the kerf. Kerf is the void created by the plasma cutting process, or the amount of metal removed by the plasma arc. By carefully controlling these variables, the operator can minimize or eliminate dimensional problems and the associated costs of secondary operations or scrap parts. With so many variables in the cut quality equation, how does a plasma torch operator begin to troubleshoot a cut quality problem? Here we discuss the critical process variables that affect dimensional accuracy of a plasma cut piece. Some of these cut quality problems are caused by mechanical and electrical problems of an old or poorly maintained cutting machine others are related to the plasma process itself. This will help it make a stronger conductive electrical charge.Many fabrication shops spend a lot of time and money reworking parts that were cut on the plasma machine to remove dross or correct dimensional inaccuracies. Use an emery cloth to wipe off the cutting tip so that it has a shine to it. Like a battery cable, this will cut down on the amount of charge it can build up. Clean TipĪfter some use, the tip can build up a lot of dust. Make sure you take the time to clean the surface of any dust, oil, rust, or other contaminates that can hamper the electrical current.
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Since the plasma cutter works through making a conductive connection with the piece that it is cutting, you will see problems when the metal surface is dirty. Keep a supply of new cutting tips on hand so you can quickly change them. If it gets any larger the conductivity of the electric charge will not work as efficiently. As the cutter is working, it will burn back the tips so that the cutting hole is misshapen. One inherent problem with the plasma cutter is that it can burn through tips very quickly. When this happens you should stop cutting and wipe off the end of the tip to clean it of any dust or slag. This slag, or metal dust, can cause the electrical current to discharge and not make a good connection. Clogged Cutting TipĪs the plasma cutter is working, there is a tendency to collect dirt particles and metal slag. Make sure that you can keep this level maintained. The cubic feet per minute rating on the air compressor should be set at the specified amount that is determined in the owner's manual. Keep Air Pressure UpĪs the cutter is working, the built in air compressor does the work of blowing away the cut material and debris. Make sure the connections on the ground clamp are good. This completes the circuit so that the cutter can create the charge it needs to melt away the metal. There is a grounding clamp that must be connected to the workpiece, near where you are making your cut. The plasma cutter must also be grounded through the workpiece. The plasma cutter must be grounded correctly in order for the electrical arc to work. The outlet may have the third prong available, but it isn't set up as a true grounded outlet. One of the problems people run into with plasma cutters is that they do not plug them into 3 pronged, grounded outlets.