plasmacutting

Plasma cutting is a metal fabrication process that uses a directed stream of ionized gas, or plasma, to cut through electrically conductive materials. The process combines an electrical arc with a jet of high-velocity gas to melt and blow away the material along the cut line.

A plasma torch passes compressed gas through a constricted nozzle while an electrode creates an electric arc to ionize the gas, forming plasma that reaches temperatures of roughly 20,000 to 30,000 degrees Celsius. The plasma jet is directed at the workpiece, melting the metal at the tip and blowing away the molten material with the gas stream.

Typical system comprises a power supply, a handheld or mechanized torch, consumables such as electrodes and nozzles, and a ground clamp. Some systems are integrated with CNC tables or robotic arms for automation. Air or inert gas assist is used depending on material and cut quality.

Plasma cutting works on electrically conductive metals, including carbon steel, alloy steel, stainless steel, and aluminum, as well as some copper and brass. It cannot cut non-conductive materials directly. Cut quality depends on thickness, gas type, and nozzle design; kerf width increases with sheet thickness. Plasma is efficient for thick sections but may produce rougher edges and more heat-affected zone compared with laser or waterjet.

Advantages include fast cutting speeds, relatively low equipment cost, and suitability for thick materials; limitations include lower edge quality on thin stock, heat-affected zone, and fumes requiring ventilation. It is commonly used in fabrication, construction, repair, and signage.

Safety considerations include the handling of high-temperature arc, molten metal, bright plasma, fumes, and noise. Protective equipment such as welding helmets or safety glasses with appropriate shading, gloves, and ventilation or fume extraction is recommended; operators should be trained to prevent burns and fires.