Time to read: 6 min
Plasma cutting, once deemed unsuitable for aluminum due to its low melting point, is now a viable and efficient method for cutting this material. Advancements in technology have led to the development of techniques that allow for precise and effective aluminum cutting.
Plasma Cutting Aluminum: Process and Tips
- Sketch out large pieces before cutting to ensure accuracy.
- Avoid dragging the cutter to prevent damage and ensure smooth operation.
- Use a drag tip for tracing templates, considering aluminum's sticky nature when warm.
- Balance amperage and cut travel speed for optimal penetration.
- Correct torch placement prevents melting issues.
- Choose the right plasma cutter based on aluminum sheet thickness.
How to Plasma Cut Aluminum
The process involves selecting the right gas mixture, nozzle, and settings for effective cutting.
- Gas: Using nitrogen and argon-helium mixtures for thicker aluminum, and compressed air with nitrogen for thinner sheets ensures clean cuts.
- Nozzle: Made from copper alloy for heat and electricity conductivity, the nozzle size affects arc size and voltage.
- Settings: Consult machine manuals for amperage and torch speed, with cutting speeds ranging from 1695 mm/m to 4750mm/m depending on voltage and thickness.
Safety Hazards and Precautions
Plasma cutting aluminum can be dangerous due to the production of hydrogen gas, which can ignite and cause explosions.
- Use a tank with a water level control option to release hydrogen molecules.
- Wear protective gear, including a welding helmet, goggles, gloves, and boots.
- Install an aerator and bubble muffler to reduce hydrogen buildup and associated risks.
- Avoid cutting anodized aluminum, aluminum floor plates, and aluminum-lithium alloys due to their reactivity with plasma cutters.
Plasma Cutting vs. Laser Cutting
When comparing plasma and laser cutting for aluminum, consider factors such as precision, cutting range, equipment and operational costs, and productivity.
- Precision: Laser cutting offers higher precision for thin sheets, while plasma cutting is more precise for thicker aluminum.
- Cutting Range: Plasma cutters have a higher cutting range but are limited to conductive materials.
- Equipment and Operational Costs: Laser cutters are more expensive to acquire and operate.
- Productivity: Laser cutting is faster for thin metals, but plasma cutting maintains productivity with thickness increase.
Conclusion
Plasma cutting is a powerful technique for cutting aluminum, offering high precision and versatility. With the right equipment, settings, and safety measures, it is possible to achieve high-quality aluminum cuts that meet industry standards.