What is plasma cutting?Plasma cutting is a process of cutting conductive metals using a high-temperature stream of ionized gas (a plasma arc). This method, created by combining electrical energy with gas transformed into plasma, forms the basis of fast, clean, and high-precision cutting operations in today’s industry.Plasma is the ionized state of gas formed through high temperature and electrical energy. This ionized gas exits a narrow nozzle at high speed and instantly melts the metal it comes into contact with, creating the cut. Thanks to the intensity of the arc energy, the cut line is narrow and clean, making plasma cutting a versatile solution in the industry.How Does Plasma Cutting Work?The plasma cutting process essentially takes place through the following steps:The power supply creates an electric arc between the electrode at the torch tip and the workpiece.The gas passing through the torch (air, nitrogen, oxygen, argon–hydrogen mixtures) is transformed into plasma by the effect of this arc.The plasma exits the narrow nozzle at high speed and strikes the surface of the material.The metal melts due to the plasma’s temperature, which can reach 20,000–30,000 °C.The molten metal is ejected at high pressure in the cutting direction, and the cut is completed. This process provides higher speed, greater control, and a smoother cut surface than a torch cut.Where Is Plasma Cutting Used?Plasma cutting is preferred in many industries thanks to its high speed, high precision, and broad material compatibility, including:Steel constructionShipbuilding and shipyardsAutomotive and heavy industryAgricultural machinery manufacturingPressure vessel and boiler fabricationMetal furnitureMaintenance and repair workshopsCNC plasma cutting machinesIndustrial production linesIt can be used in both manual torch systems and CNC-controlled automatic machines.Chracteristics of Plasma CuttingThe main characteristics that distinguish plasma cutting from other methods:Extremely high temperature and speedSmooth cutting of both thin and thick materialsPrecise contour cutting (holes, cavities, shapes)Narrow heat-affected zone (HAZ)Ability to cut metals that cannot be cut with oxygenSuitable for both manual and CNC useIt is one of the most efficient methods, especially for carbon steel, stainless steel, and aluminum.Which Materials Can Plasma Cutting Be Used On?Plasma cutting can be applied to all electrically conductive metals:Carbon steelStainless steelAluminumCopper and copper alloysCast ironTitaniumThese are materials that are difficult or impossible to cut using oxy-fuel cutting.Advantages of Plasma CuttingPlasma technology offers numerous advantages in both manual use and CNC machines: 1. High Cutting SpeedPlasma is significantly faster than traditional oxy-fuel cutting.For example, it can cut 10 mm sheet metal 3–5 times faster.2. Clean and Smooth Cut Surface Thanks to its high arc energy, slag formation is minimal.This reduces the need for post-cut grinding.3. Versatile Application It delivers effective results in all types of cutting, such as: Thick sectionsThin sheetsManuel cuttingCNC cutting4. Wide Material Compatibility It performs well even on materials that cannot be cut with oxygen.5. Low Heat Impact Thanks to its narrow heat-affected zone (HAZ), the risk of metal distortion is reduced.6. Cost-Effective Long-lasting consumablesLow energy consumptionHigh cutting speed reduces overall production costsTypes of Plasma Cutting1. Manual Plasma Cutting These are cuts made with portable plasma cutting machines.Ideal for service and maintenance teams, workshops, and small businesses.2. CNC Plasma Cutting Computer-controlled, high-precision cutting.Preferred for thick plates, heavy workloads, and mass production.3. Hyper Plasma / High-Performance Systems It is used in jobs requiring high-level quality by offering the following:• A narrower arc• Higher speed• Minimum slope on the cutting surfaceWhich Gases Are Used for Plasma Cutting? Different gases affect cutting performance and edge quality:Air → Most common and economicalOxygen → High speed on carbon steelNitrogen → Good surface finish on stainless steel Argon–Hydrogen → Thick and precise stainless steel cuts Argon → Thin materials Compressed air is generally preferred in manual machines.How to Choose a Plasma Cutting Machine?When selecting the right plasma cutting machine, the following criteria are important:1. Cutting Capacity (mm)The machine’s piercing ability, quality of cut, and maximum severance cutting values should be considered.2. Power (Amperage)• 40–60 A → Thin sheets• 80–120 A → Medium thickness• 120 A and above → Heavy industry3. Duty CycleA high duty cycle is critical for businesses with intensive production.4. Consumable LifespanThe durability of torch consumables directly affects operating costs.5. Compressor Requirement Some plasma machines have built-in compressors, while others require an external compressor.6. CNC Compatibility Important for businesses planning automation investments.7. Portability Light and compact models are preferred for field and service work.ConclusionPlasma cutting is a modern metal cutting method that offers speed, precision, cost-effectiveness and broad material compatibility. This technology, used on both manual and CNC machines, enhances production quality and efficiency across numerous industries.Selecting the correct plasma machine; determining the right power, gas and consumable combination is critical as it directly affects cutting quality, cost and production speed.
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