What are plasma cutting machines used for?
Plasma cutters are used to cut conductive metal materials, such as steel, stainless steel, aluminium, and copper. Thanks to plasma technology, it is possible to perform fast, precise, and clean cuts, even on thick materials. This technique is mainly used in industrial contexts, for professional and semi-professional applications, but also for artisanal and hobby work, thanks to the wide range of machinery available that covers different needs.
Plasma cutters are suitable for various activities, including:
- Cutting metal sheets: plasma technology allows cutting sheets of different thicknesses with ease and precision, avoiding distortions in the material.
- Industrial and mechanical repairs: often used for maintenance and repair work on metal components in industrial plants, these machines ensure speed and precision in cuts.
- Craft projects and customizations: the versatility of plasma makes it possible to create shapes and designs on sheets, making this technology ideal for design and customization work as well.
This technique is suitable for every need, as it allows cutting sheets of any thickness.
Manual plasma torches can cut sheets up to 50 mm thick, while automatic ones can cut sheets up to 130 mm.
Cutting can be performed with small torches, but also with large industrial machines that can cut sheets up to 100 mm.
How are plasma cutters made?
Plasma cutters consist of several key components that determine their operation and effectiveness. Below are the main components of a plasma cutting machine:
- Plasma generator: it is the heart of the machine, responsible for generating the plasma arc. This component converts electrical energy into heat, creating a plasma jet that reaches extremely high temperatures, necessary to melt the material to be cut.
- Cutting torch: the torch is the tool the operator uses to guide the plasma jet onto the material to be cut. Inside it are electrodes and nozzles that control the plasma flow, ensuring a precise and direct cut.
- Cooling system: essential to prevent the machine from overheating during operation. Some models use an air cooling system, while others, more advanced, use a liquid cooling system to ensure greater operational efficiency.
- Air compressor (optional): in models with an integrated compressor, this component generates the compressed air necessary for the plasma ionization process. In models without a compressor, an external compressor is required.
- Control panel: allows setting cutting parameters, such as amperes, speed, and operating mode. Some models offer advanced functions for optimizing the cutting process based on the thickness and type of material.
- Cables and power supply: the machine requires a stable connection to a power source, and some models are designed to be connected to a generator, ensuring flexibility in environments without a fixed electrical network.
How do plasma cutting machines work?
The operation of a plasma cutter is based on creating a highly ionized plasma jet that passes through the material to be cut, melting it and pushing away the molten metal to complete the cut. The process begins when the operator activates the torch, which emits a high-intensity electric arc between the torch's internal electrode and the workpiece. This arc heats the compressed air (or inert gas) passing through the torch, transforming it into plasma, an ionized gas that reaches temperatures above 20,000°C.
Before moving on to the detailed explanation, we would like to clarify that plasma cutting produces a lot of smoke, so the cutting machine must necessarily be used outdoors while wearing appropriate protection.
The operation of plasma cutters can be divided into several steps:
- Creation of the plasma arc: when the machine is turned on, the electric arc forms between the electrode and the workpiece. Compressed air is forced through a narrow nozzle, where it is ionized by the heat of the electric arc, transforming into plasma.
- Cutting the material: the ionized plasma is directed onto the metal through the torch, melting the material. The pressure of the compressed air or gas pushes the molten material out of the groove created by the cut, leaving a clean and precise edge.
- Power control: the power level, expressed in amperes, directly influences the cutting capacity. The higher the current, the thicker the material the machine can cut. More powerful machines, with amperes reaching up to 300, can cut materials with high thicknesses, up to 20 mm or more.
- Work cycle and cooling: during operation, plasma cutting machines accumulate heat. To prevent overheating, a work cycle is provided, which establishes the maximum continuous use time followed by a cooling period. Machines with a 35% duty cycle at 300A, for example, can operate for 3.5 minutes every 10 minutes of operation, leaving the remaining 6.5 minutes for cooling.
Models with an integrated compressor are more practical in environments where an external source of compressed air is not available. This feature allows the use of machines in open spaces or for mobile operations. Additionally, modern plasma cutting machines are designed to be used with generators, allowing them to operate in environments without direct access to the electrical grid, supporting voltage fluctuations up to +/- 30%.
Advantages of plasma cutting
Plasma cutting machines offer a range of advantages compared to other cutting techniques such as oxy-fuel cutting or mechanical cutting. The main advantages are as follows:
- Cutting speed: plasma allows for much faster cuts compared to other methods, such as oxy-acetylene or disc cutting, making this technology ideal for large-scale operations or for those who need to work quickly on multiple pieces.
- Precision: thanks to the thin plasma column, it is possible to obtain clean edges and very precise cuts even on reduced thicknesses. This reduces the need for post-cut finishing, saving time and resources.
- Versatility on materials: plasma cutting can be used on a wide range of conductive metals, including steel, aluminium, copper, and various alloys. This ability to work on materials with different properties makes it suitable for multiple applications, both industrial and artisanal.
- Reduction of thermal deformations: compared to oxy-acetylene cutting, plasma generates less heat, reducing the risk of deformations in the material. This is particularly useful when working with thin sheets or materials that are heat-sensitive.
Plasma cutting also stands out for some advantages over other metal cutting systems. For example, compared to oxy-fuel cutting, plasma can be used on a greater number of metals, including non-ferrous ones like aluminium and copper, which cannot be cut with the oxy-acetylene system. Additionally, unlike mechanical cutting, it does not require direct contact between the blade and the metal, reducing wear and extending the life of the tools.
Technical features of plasma cutting machines
The plasma cutters available on AgriEuro share some fundamental technical features that determine their performance and versatility in different applications. Below is a brief description of the main technical specifications to consider.
- Maximum amperes: indicate the power of the machine and directly influence the maximum cutting thickness of the material. The higher the number of amperes, the thicker the metals that can be cut. The machines on AgriEuro offer amperes ranging from 25 to 300, allowing work with thicknesses up to 20 mm. A higher amperage value is useful for industrial applications, where deep cuts and on resistant materials are required.
- Duty cycle at 40°C: the duty cycle at 40°C indicates how long a machine can operate without interruption before requiring a cooling phase. For example, a machine with 300A at 35% can work for 3.5 minutes over a 10-minute period, with the rest of the time dedicated to cooling. The duty cycle becomes more favourable at temperatures below 40°C, allowing prolonged use of the machine before overheating affects performance.
- With or without integrated compressor: models with an integrated compressor offer the advantage of not requiring an external source of compressed air, making the machine more autonomous and suitable for mobile applications or in environments with limited resource availability. Machines without a compressor, on the other hand, while requiring an external compressor, tend to ensure greater power and flexibility in more complex operations.
- Maximum cutting thickness: the maximum cutting thickness represents the machine's ability to work on metals of different thicknesses. The plasma cutters on AgriEuro can cut metals with thicknesses ranging from 8 mm to 20 mm, allowing you to select the most suitable machine based on your work needs.
- Generator +/- 30%: some machines can be connected to a power generator, allowing them to operate even in environments without a fixed electrical network. These models are designed to tolerate voltage fluctuations up to +/- 30%, making them extremely versatile in situations where the power supply may be unstable.
Plasma cutter buying guide
When choosing a plasma cutting machine, it is essential to consider some technical features to ensure you purchase the product that best suits your needs.
The factors to consider include:
- Power and amperes: for those working on high metal thicknesses, a machine with higher amperes is indispensable. If working on thinner materials or performing precision activities, models with lower amperes may be more suitable.
- Duty cycle: it is important to check the machine's duty cycle, especially if you intend to use it for prolonged sessions. A high duty cycle allows the machine to be used longer without interruptions for cooling.
- Integrated or external compressor: those working in mobile environments or needing a more compact and autonomous machine might prefer a model with an integrated compressor. Conversely, those requiring high power might opt for a machine with an external compressor.
- Generator compatibility: if working in places without an electrical network, the ability to connect the machine to a power generator becomes an essential advantage.
Types of customers
Based on these features, there are different types of customers for whom plasma cutters are particularly suitable:
- Industrial professionals: for those working in production environments where it is necessary to cut high thicknesses on a large scale. In this case, a powerful machine with high amperes and a high duty cycle is indispensable.
- Artisans and blacksmiths: for precision work and for creating details on thinner metal materials, a machine with medium power and an integrated compressor can be ideal.
The best brands of plasma cutters available on AgriEuro
Buying from reliable and recognized brands is essential to ensure performance, reliability, and durability over time. On AgriEuro you can find some of the best brands of plasma cutting machines, here are the main ones:
- Awelco plasma cutters: Awelco is a brand specialized in the production of welding and plasma cutting machines. It offers reliable and easy-to-use solutions, particularly appreciated for their quality-price ratio.
- GYS plasma cutting: GYS is a French company known for its technologically advanced solutions, specializing in welding and cutting equipment. Its plasma cutting machines are appreciated for their power and cutting precision, making them ideal for professional use.
- Helvi plasma cutting machines: Helvi is an Italian brand that produces welding and plasma cutting equipment. It is known for its reliability and robust machines, suitable for both professionals and advanced hobbyists.
Why buy plasma cutters on AgriEuro?
Buying a plasma cutting machine on AgriEuro offers numerous advantages that make the purchasing experience safe, fast, and convenient. Here are the main reasons to choose AgriEuro:
- Fast and free shipping: AgriEuro offers fast and free shipping, managed by its own logistics centres, ensuring reduced delivery times throughout the territory.
- Spare parts always available: it is possible to order original spare parts for each purchased product, ensuring maintenance and durability of the machines over time.
- Attentive and personalized after-sales assistance: AgriEuro offers a dedicated customer service, ready to provide technical assistance and advice tailored to the specific needs of each customer.
Thanks to these advantages, AgriEuro stands out as the reference point for purchasing plasma cutting machines, offering solutions for every type of need. Discover the complete offer now and choose the plasma cutting machine that best suits your needs.
FAQ on plasma cutting machines
1. How does plasma cutting occur?
Plasma cutting occurs through the use of an ionized gas that becomes plasma when exposed to an electric arc. This process begins with the creation of an electric arc between an electrode inside the torch and the workpiece. The arc heats the gas to extremely high temperatures, up to about 30,000°C, causing it to transition from a gaseous state to plasma. This plasma is so hot and concentrated that it can melt the metal.
- Creation of the electric arc: The arc ionizes the gas, generating plasma.
- Melting of the metal: The plasma reaches a temperature capable of instantly melting the metal at the point of contact.
- Removal of molten material: A high-speed gas jet removes the molten metal, creating a clean cut.
Plasma cutting is particularly effective for conductive materials such as steel, stainless steel, aluminium, copper, and brass. It is used in industrial and artisanal applications to cut metals of different thicknesses with precision, speed, and relatively low costs compared to other techniques like laser cutting.
2. What gas is used for plasma cutting?
The gas used in plasma cutting plays a fundamental role in the process, as it directly affects the quality of the cut and speed. Different gases can be used, depending on the type of material to be cut and the desired result.
- Compressed air: The most commonly used gas. It is economical and suitable for most metals, such as carbon steel and aluminium. However, it may cause slight oxidation on the edges.
- Nitrogen: It is the preferred gas for cutting stainless steel and aluminium. Being inert, it prevents oxidation, producing cleaner edges.
- Argon-hydrogen: This mixture is used for high-precision cuts on thick and resistant materials, such as thick stainless steel and aluminium.
- Oxygen: Offers superior cutting speed and optimal edge quality for carbon steel. It reduces slag build-up and improves penetration speed into the material.
3. How precise is plasma cutting?
Plasma cutting is renowned for its precision, although it can vary based on the machine configuration, material thickness, and gas used. The plasma jet allows for a clean and accurate cut, with a relatively smooth edge and reduced slag. This makes it ideal for industrial applications where high precision is required, while maintaining a high processing speed.
- Material thickness: The greater the thickness, the lower the precision. However, with the correct gas and settings, plasma is effective on medium and thin thicknesses.
- Feed speed: The speed at which the plasma torch moves affects the edge quality. A cut that is too fast may leave slag or rough edges, while a cut that is too slow may cause deformations.
- Gas control: The selection and regulation of the gas, along with torch management, are essential to maintain uniform cutting quality.
4. What materials can be cut with plasma cutters?
Plasma cutting is particularly suitable for conductive metal materials, exploiting the principle that only these materials can form an electric arc necessary to create plasma. It is mainly used in industrial applications for cutting sheets and metal pieces.
- Carbon steel: One of the most common materials cut with plasma. This type of steel is widely used in various sectors due to its workability.
- Stainless steel: Ideal for cutting with plasma, especially with gases like nitrogen or argon-hydrogen, which prevent edge oxidation.
- Aluminium: Aluminium can be cut with plasma, although it requires a specific configuration to avoid thermal deformations.
- Copper and brass: Non-ferrous metals that can be cut, although they require careful management to avoid slag and irregular edges.
Plasma can cut materials with thicknesses ranging from a few millimetres to several centimetres, making it versatile for many industrial applications.
5. At what temperature does plasma cutting occur?
Plasma cutting occurs at extremely high temperatures, which can reach about 30,000°C. This heat is generated when a gas, such as compressed air, nitrogen, or argon, is ionized by the electric arc between the electrode and the workpiece. The high temperature of the plasma allows for rapid melting of the metal and precise cutting.
- Plasma has a higher temperature than other cutting methods like oxy-acetylene flame cutting.
- The high temperature allows plasma to cut metals with speed and precision, especially conductive materials.
- Thanks to the intense heat, plasma can cut materials of various thicknesses, from thin sheets to thicker materials, even several centimetres.
The extremely high temperature of plasma is one of the main characteristics that makes this method so efficient for cutting metals.
6. What is the difference between plasma cutting and laser cutting?
Both plasma cutting and laser cutting are thermal cutting techniques used for working with metal materials, but they differ significantly in terms of operation and applications.
- Energy source: Plasma cutting uses an ionized gas (plasma) that reaches high temperatures to melt the metal. Laser cutting, on the other hand, uses a concentrated laser beam that vaporizes or melts the material.
- Materials: Plasma is effective only on conductive materials, while laser can cut both metals and non-metallic materials like plastics and wood.
- Precision: Laser is generally more precise than plasma, thanks to the extremely thin beam, which allows for very detailed and clean cuts, especially on thin sheets.
- Thickness: Plasma cutting is more suitable for thicker materials, while laser is more efficient on reduced thicknesses.
- Cost: Laser cutting machines are more expensive and require more maintenance than plasma cutting machines, making the latter more economically accessible.
The choice between laser cutting and plasma cutting depends on the specific needs for precision, thickness, and materials to be worked.
7. How to choose a plasma cutting machine?
The choice of a plasma cutting machine depends on several factors, including the specific needs of the user, the type of materials to be cut, and the frequency of use. Below are some criteria to consider when choosing:
- Material thickness: It is important to choose a machine with a cutting capacity that matches the thickness of the materials you intend to work with. More powerful machines are necessary for cutting thick materials.
- Type of materials: Some machines are optimized for specific materials like stainless steel, aluminium, or carbon steel. The choice of gas to use is linked to this criterion.
- Portability: If the machine needs to be moved frequently, it is advisable to opt for a portable and lightweight version.
- Power supply: Plasma cutting machines can operate with different voltages (single-phase or three-phase). You must ensure that the machine is compatible with the available power supply.
- Cutting quality: Some machines offer greater precision and cutting quality, reducing the need for post-cut processing.
The power of the machine, the ease of use, and the operating costs are other determining factors in choosing suitable equipment.
8. How to maintain a plasma cutting machine?
The maintenance of a plasma cutting machine is essential to ensure a long life and optimal performance. Regular maintenance not only improves cutting quality but also prevents breakdowns and malfunctions.
- Cleaning the torch: The plasma torch must be cleaned regularly to remove any slag and molten metal residues that could obstruct the gas passage.
- Replacing electrodes and nozzles: Electrodes and nozzles tend to wear out with use, so it is essential to check them regularly and replace them when they show signs of wear to maintain high cutting quality.
- Checking the gas: It is important to check that the gas flow is regular and that there are no leaks. Correct gas pressure is essential for efficient cutting.
- Checking cables and connections: Cables and connections must be inspected for signs of wear, damage, or short circuits. Damaged cables can affect the arc's power and operational safety.
- Cleaning the air filter: If the machine uses compressed air, the filter must be cleaned regularly to ensure an impurity-free air flow, which could compromise cutting quality.
Careful and periodic maintenance helps prevent problems and ensures a longer life for the equipment, as well as maintaining high safety standards.
