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  • Plasma Cutting

    What is Plasma Cutting?

    Continuing to energize the substance under the right conditions while the substance is in a gaseous state causes the substance or metal to go into plasma. The source of energy can be electricity, or, in plasma cutting, this source can be thermal or beam based.

    The most important difference that separates the plasma phase from the gas phase is that it conducts electricity, it is at very high temperature and it emits light. The plasma state of matter is composed of free-floating electrons and atoms (ions) that have lost their electrons. Today, plasma cutting has evolved technologically and is used in manufacturing and industry, medicine, lighting, televisions, energy production (nuclear) and many other technologies. It contains equal amounts of positive and negative charges in plasma formation. Most of the principles that apply to all electrically conductive materials also apply to plasmas. Like plasma, plasma cutting is also affected by electric field and magnetism. They are classified according to plasma temperatures and charged particles in their volume. The luminescence in fluorescent lamps, blue light seen during welding, lightning and lightning are also plasma. There are different types of plasmas in the sun. The auroras that appear at the poles are also a kind of plasma. As a result, it can be used in metal cutting.

    How Does Plasma - Oxygen Cutting Work?

    We do this plasma cutting with the help of a thermal saw. Plasma-oxygen cutting is simply ionizing the gas flowing in the torch partially by energizing it, in other words transforming it into plasma, the resulting high-temperature plasma shifting from the nozzle mouth to the positive pole material with the effect of the gas flow, melting the material, namely the metal, and removing the melting material by jet effect. performed with. Most commonly, metal sheets with a thickness of 1-80 mm (optimum 1-32mm) are cut in the plasma sheet cutting process in the industry. The industrial parts that benefit most from plasma cutting are railways, wagon industry, shipbuilding industry, (shipyards), mechanics, pressure vessel manufacturers (degasser, water tanks, hot water boilers impregnation, heating boilers).

    Plasma Sheet Cutting System

    In general, a plasma sheet cutting system for automation should have the following elements

  • Power source: It is a direct current source. It provides constant direct current at high voltage. In the process, it provides the necessary energy to maintain the continuity of the plasma after ionization. High frequency ignition circuit: It is the circuit that creates alternating current between 5000 and 10000 volts at 2MHz. Ignites the pilot arc required for the ionization of the carrier gas.
  • Gas console: It is used to adjust the flow rates of the carrier (plasma) and shielding gas, mixing ratios and to select the plasma gases. Today's plasma cutting machines are electronically controlled.
  • Torch: It is the part that holds the nozzle, electrode nozzle, nozzle outer cover, protective head and cover together in which plasma gas and shielding gas flow. It is designed to create and focus plasma. It also provides shielding gas and shielding gas and coolant flow. There are specially designed channels and electrical connections for the body. The carrier system and the control system provide torch movement and control of the entire system. The cooling system also allows the coolant to circulate within the system. The aspirator system also removes the gas and smoke generated during plasma cutting from the work area. When the plasma cutting process starts, a signal from the power supply simultaneously turns on the open circuit voltage and gas flows into the torch of the plasma cutting machine. In the system, the nozzle and material are connected to the positive pole of the power source and the electrode to the negative pole. The carrier gas begins to flow through the nozzle orifice, passing through the space between the nozzle and the electrode. Meanwhile, the high frequency ignition circuit creates high frequency arcs between the nozzle and the electrode. The carrier gas is partially ionized with the energy coming from these arcs.With the thrust effect of the gas at high flow velocity, it directs the positive pole of this flow path outward(from the nozzle to the metal surface cut with plasma).With the material in the positive pole, the residual current circuit is completed and the high frequency circuit is closed.As a result of the continuous ionization of the gas, plasma formation is provided by the energy coming from the direct current circuit.The plasma method obtained in this way is called the stone arc method.The plasma cutting process starts with the local melting of the metal surface due to the high temperature of the plasma and the carrier gas at high flow velocity sprays the molten metal and makes a hole in the material.In the meantime, the torch carries out the cutting process by moving at a speed that will not lose the continuity of the arc with the carrier system.Plasma cutting process is generally carried out by the carried arc method.
  • Non-Carrying Arc Method

    Another plasma cutting method is the non - carried arc method.Torch technology is different in this technology.The plasma arc starts between the nozzle and the electrode before it is transferred to the material, that is, the metal to be cut or drilled, and the plasma comes out in the form of a flame at the torch tip without losing its continuity with the effect of flowing gas.Generally, this method is used for non - metal materials.It is suitable to be used in surface coating process.Materials we can cut in plasma cutting process: Alloy steel, stainless steel, carbon steel, aluminum alloys, titanium and copper and alloys are cut.Metal sheets and pipes with Nickel Titanium and its alloys may only be suitable for cutting and preparing the material before machining.In plasma cutting of these metal materials, roughness and color change is observed on the cutting edge and surface.During plasma cutting of metals, combinations of plasma gases, flow rates of gases and thickness of metal material affect the cutting quality.Various gases and mixtures are used as carrier and shielding gas to achieve a good cut quality in CNC plasma cutting systems.The ionization energies between the plasma cutting gases to be used depend on the thermal conductivity and reactivity properties.

    Nitrogen, oxygen, and argon-hydrogen gases are the most used gases. The standards that determine the quality in CNN plasma cutting are thermal cutting standards such as ISO9013, DIN 2310. Cutting surface angle (steepness) and smoothness, as well as cutting edge roundness, beard formation, upper fallout and slit spacing are the most important criteria that determine the quality in CNN plasma cutting. In CNC plasma cutting, the cutting surface angle is the amount of curvature that occurs on the cutting surface. It is generally determined by the steepness value. To give practical values, the slope in CNC plasma cutting varies between 1-3 degrees on the material side and 3-8 degrees on the inert material side. In straight flow torches, a cutting angle of 4-8 degrees is considered normal.

  • Smoothness: It is measured on the upper or lower surface of the cut surface at the distance and intervals defined in standards. Generally, this value is determined and influenced by the cutting speed, gas flow rate, torch movements.
  • Cutting line lines: It is the ripple that occurs along the cutting surface of the cut sheet material. The gas used, the continuity of the power supply output, the torch structure, the shaking (vibration) in the mechanical system all affect the quality in this regard.
  • Top cutting edge roundness: It is a characteristic feature in plasma cutting and is caused by the longer interaction of the upper surface of the material with the plasma arc. This roundness is more visible on thin, ie low-thickness surfaces, this effect is minimal.
  • Burr: It is formed by the melting of the metal that the plasma cut and melted during plasma cutting and condensation to the back surface of the cut surface.
  • Cutting range: It is the opening created by the plasma while cutting the metal during plasma cutting. A cutting gap of one or two times the nozzle opening is normal, and if it is more, it reverses the situation. The clearance between the torch and the metal part being cut is also important. When describing plasma cutting, the final quality determining factor is the upper spatter. The burr on the upper surface. The distance between the cut sheet metal surface and the torch is the primary factor in the formation of burr and the formation of upper fallout. It may also occur due to a worn nozzle.