To cut a straight line, follow a straight edge. Plasma cutting allows this because it does not create the wide heat-affected zone that can melt or burn a metal, wood, or cardboard edge.
For shapes you cut regularly, use a permanent metal template. For example, artist Eddie Dean, owner of Texas Silhouette, Midland, Texas, often starts the creative process with a digital picture. Once he has the digital image, he loads it into his computer and prints out a paper copy. He then projects that image on a wall to blow it up.
Using a special type of board for artwork (image poster board with metal on the back of it), Dean traces the projected image and adds last-minute details. Using a razor blade, he cuts out the pattern. Finally he lays the pattern on a sheet of 1/8-in.-thick mild steel and uses soapstone to trace the pattern and all its intricate details.
For fine detail, Dean holds the tip of the torch a fraction of an inch from the workpiece.
"The closer you hold the torch to the metal, the finer the cut," he said. "If you raise the tip up, it makes a wider cut. Under normal circumstances, my cut width is 0.040 to 0.050 in." It's important to note, however, that not all machines can cut this precisely.
Plasma cutters also can relieve physical stress. For example, U.S. Plumbing and Heating fabricator Layton Dilley used to cut pipe fittings with offset snips.
"Because I had to grip the snips so hard to cut the metal, I'd have to take regular breaks to relieve fatigue," he said. "With a plasma cutter, I can zip right through the cutting without stopping."
How to Use a Plasma Cutter
A plasma cutter works by a high-velocity stream of ionized gas, known as plasma, to melt and cut through metal with precision and efficiency. It is achieved by passing an electrical current through a gas, such as air or nitrogen, which ionizes the gas and creates the plasma stream. The plasma stream is then directed through a small nozzle and onto the metal, which melts and cuts through the material.
If you've ever cut with a hacksaw, you already know the basics of using a plasma cutter! It's important to ensure that your metal piece is stable and level, held down with clamps or other means. Plasma cutters need to be able to heat up quickly and can overheat if they aren't in direct contact with the metal piece directly.
Next, make sure your plasma cutter is in good condition. Check the power box for blown fuses and replace any that are missing. Test the air pump, ensuring it's blowing hard enough to produce a good arc.
Once your cutter is ready, place it on the metal so it's at a good working angle (typically around 45 degrees). Plug it in and turn on the air pump and voltage supply. Then, turn on the plasma arc! As you hold down the trigger button and pass through the metal, you should see your cut line form right before your eyes.
When making long cuts, you may need to stop and move the plasma cutter several times. Don't worry, and this is all normal! If you have a hand-held air hose and an air regulator, hold down the trigger button for a few seconds before moving it to the new cut line. This way, it will be easier for you to start up again because there will be a small amount of hot metal left from where you just cut.
For shapes you cut regularly, use a permanent metal template. For example, artist Eddie Dean, owner of Texas Silhouette, Midland, Texas, often starts the creative process with a digital picture. Once he has the digital image, he loads it into his computer and prints out a paper copy. He then projects that image on a wall to blow it up.
Using a special type of board for artwork (image poster board with metal on the back of it), Dean traces the projected image and adds last-minute details. Using a razor blade, he cuts out the pattern. Finally he lays the pattern on a sheet of 1/8-in.-thick mild steel and uses soapstone to trace the pattern and all its intricate details.
For fine detail, Dean holds the tip of the torch a fraction of an inch from the workpiece.
"The closer you hold the torch to the metal, the finer the cut," he said. "If you raise the tip up, it makes a wider cut. Under normal circumstances, my cut width is 0.040 to 0.050 in." It's important to note, however, that not all machines can cut this precisely.
Plasma cutters also can relieve physical stress. For example, U.S. Plumbing and Heating fabricator Layton Dilley used to cut pipe fittings with offset snips.
"Because I had to grip the snips so hard to cut the metal, I'd have to take regular breaks to relieve fatigue," he said. "With a plasma cutter, I can zip right through the cutting without stopping."
How to Use a Plasma Cutter
A plasma cutter works by a high-velocity stream of ionized gas, known as plasma, to melt and cut through metal with precision and efficiency. It is achieved by passing an electrical current through a gas, such as air or nitrogen, which ionizes the gas and creates the plasma stream. The plasma stream is then directed through a small nozzle and onto the metal, which melts and cuts through the material.
If you've ever cut with a hacksaw, you already know the basics of using a plasma cutter! It's important to ensure that your metal piece is stable and level, held down with clamps or other means. Plasma cutters need to be able to heat up quickly and can overheat if they aren't in direct contact with the metal piece directly.
Next, make sure your plasma cutter is in good condition. Check the power box for blown fuses and replace any that are missing. Test the air pump, ensuring it's blowing hard enough to produce a good arc.
Once your cutter is ready, place it on the metal so it's at a good working angle (typically around 45 degrees). Plug it in and turn on the air pump and voltage supply. Then, turn on the plasma arc! As you hold down the trigger button and pass through the metal, you should see your cut line form right before your eyes.
When making long cuts, you may need to stop and move the plasma cutter several times. Don't worry, and this is all normal! If you have a hand-held air hose and an air regulator, hold down the trigger button for a few seconds before moving it to the new cut line. This way, it will be easier for you to start up again because there will be a small amount of hot metal left from where you just cut.
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