Laboratory Manual

For

Air Plasma Cutting

Machine

1
INTRODUCTION

The Plasma Arc Cutting system employs the use of an

electric arc and a pressurized volume of ionized air forced

through a small orifice (TIP) fitted between the electrode in

the plasma torch and the work piece to be cut. This

constricted, high speed and high temperature plasma arc

stream cuts through metal in a concentrated localized area

and the molten metal is blown away by the high velocity

arc and air steam.

The Plasma Arc Cutting process is capable of cutting and

gouging most Ferrous (steel) and Non-Ferrous (Aluminum,

Copper etc) metals producing a clean narrow cut width

(determined by the tip orifice size) and smoother surfaces.

The process is more portable, cuts faster and cleaner than

the gas cutting (oxy/fuel) process, requiring no pre-heat,

and with the added advantage of being able to cut Stainless

2
Steel and Non-Ferrous metals (oxy/fuel cannot) cleanly and

effectively, using less cumbersome equipment. The process

can be used with either a hand held torch or on automated

systems. The Plasma Power source has drooping current

characteristics, using higher voltages than standard

welding machines and the torches are well insulated to

protect the operator against the high voltages present. The

majority of Plasma Arc Cutters today have high frequency

arc starting features meaning that non base metal contact

is used as opposed to machines without high frequency

that require scratch start to initiate the arc. Hand cutting

torches using stand-off guides (determines tip distance

from work piece) enables the operator to rest the torch on

the work piece and by using a template or straight edge is

able to cut straight or profile edges cleanly and accurately.

The torch can also be used for gouging by changing the tip

to a gouging tip that enables the operator to angle the torch

3
to + - 30 degrees as opposed to the 90 degree used when

cutting.

4
Long (extended) tips can be fitted for maximum visibility

giving a clear view of the cut to be made either in the

stand-off or drag position. The tips contain an orifice which

constricts the plasma arc. The tips come in various orifice

sizes and also gradually wear with use and must be

replaced when the arc cut becomes too wide. Due to the

alloying denseness and higher electrical resistance of

Stainless Steel the thickness of cut achieved per cutting

machine capacity is considerably lower than steel. All

manufactures of Plasma Arc Cutting equipment indicate

the cutting capacity when cutting various metals. When

cutting a circle the cut is started at the plate leading edge

towards the circle edge or a hole is pierced in the centre of

the circle and cut towards the circle edge. On piecing the

hole through the plate the torch is angled at + - 30º and

once pieced the torch is raised to a 90º position.

5
Procedure

1. Connect power supply to plasma cutter

2. Connect power supply to Compressor for Air Plasma

Cutter

3. Run compressor for enough time to get pressure of

about 6 kg/cm2

4. Connect air supply to air plasma cutter

5. Connect earth terminal to test piece

6. Perform air plasma cutting on job with cutting head.