How to avoid the top 10 problems in plasma cutting: Practical tips you can use right now February 19, 2001 By: Attention to detail at the outset can save plasma cutting operators a load of trouble during production. The old adage 'measure twice, cut once' is as important for plasma arc cutting operators as it is for carpenters.

The phrase could be reworded to 'inspect twice, cut once' for the plasma industry. Careful preparation, setup, and maintenance can alleviate many costly problems which operators encounter. Strategy The following is a list of remedies that may help operators avoid some of the most common problems encountered in plasma arc cutting.

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Replace Consumable Parts Regularly. Think about a car—changing the oil regularly is much less costly than replacing the car's engine. In the same way, replacing consumables regularly is much more cost-effective than replacing the torch. Using severely worn consumables can lead to uncontrolled arcing in the plasma chamber, which can cause torch failure. What are the signs of spent consumables? Often, deteriorating cut quality is the first sign of worn parts.

Visual inspection is important as well. If a nozzle shows signs of oxide residue on the inside, or if signs of gouging exist on the inside or outside of the nozzle, it should be replaced. To tell whether an electrode is spent, check the pitting of the electrode element.

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Depending on the gas being used, the pitting should not be deeper than 3/32 inch for oxygen or air or 1/8 inch for argon or nitrogen. If the pits are deeper than these guidelines, it is time to change the electrode. Finally, if an examination of the gas swirlers reveals cracks, arc burns, or dirt or grease in the holes, the swirlers should be changed.

Problems 2 through 5 2. Properly Assemble the Torch. Torches should last for a long time with correct care. The torch should be assembled so that the parts are in proper alignment and fit together snugly.

This ensures good electrical contact and the correct flow of gas and coolant through the torch. In addition, the torch threads should be clean, and seating areas should not have any particulate contamination.