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Torches and Torch Plasma? Oxy? Which one? How do you use them?


Torches and Torch Plasma? Oxy? Which one? How do you use them?

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  #1  
Old 11-13-2015, 09:30 AM
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Cutting Aluminum

I am cutting some aluminum with straight air (Hypertherm PowerMax 45). The AL is .130 thick and the cutting looks like hell. My feed rate maybe slower than I should be. I am planning to change the gearing to get some more speed and hopefully can get my ramp velocity fast enough to make a difference.

I am running straight air and wondering if I should be trying to run some other types of gasses. Any advise would be greatly appreciated.
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  #2  
Old 11-13-2015, 09:48 AM
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Start by looking up the recommended settings from the manufacturer. This will get you close. Amperage, speed, height, tips,etc, all play a huge part in cut quality. AL needs to be cut much faster than steel. To slow or to hot can fugly up your cut quality quickly. Each material you cut, I would advise testing the settings until you get good results. Then document them for future setups. I have a little note pad next to my table with this info for each material.
Running air is just fine.
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Old 11-13-2015, 09:50 AM
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Water separator? Air dryer? Consumable quality? Grounding? Cfpm keeping up with your machine? Many factors.
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Old 11-13-2015, 09:59 AM
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Straight cuts are usually done faster than curves. 60% or so on curves. Clock wise verses counter can play a part. With my table internal cuts are one direction and outside cuts are opposite direction.
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Old 11-13-2015, 10:25 AM
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The single biggest difference that I made when cutting AL (other then the correct travel speed) was putting in a refrigerant dryer. No matter what I did before I always had an ugly cut with lots of spiky dross. Now I have very nice cuts with little dross to clean up. Someone told me that you can also go to straight nitrogen but I don't know what's involved or the cost. Harbor Freight has a knock off air dryer that has great reviews and is only $3-400.

Thanx,
Jaysin
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Old 11-13-2015, 01:06 PM
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A easy test might be a coil off copper tube in the freezer type dryers.

I recently came across some centrifigal water seperators that seem really nice. I can send you one if you want.

Domnick Hunter - 21 CFM Water Separator
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Old 11-13-2015, 04:47 PM
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Had a customer come down to our shop today. We were cutting aluminum with .130 wall thickness. The 1.0 OD tube worked pretty well. The .750 tube on the other hand was a real pain in the a$$. We were able to get the cut ok (not as good as the 1.0) but the biggest problem we ran into was the heat up on the opposite side. As soon as we got 180 degrees around the material was already so hot that it didn't cut very well and dross all over the place. I blew air down the tube and it helped a little, but not what we want for an end product. They are thinking that Nitrogen maybe the way to go.

I think a dryer would help, however, I don't know if it would help our opposite wall heat up issue.

On a side note, it was actually a blast working with a few guys that really understood diagnosing how to set up the plasma cutter.

.
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Old 11-13-2015, 05:14 PM
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Lower your amperage and speed perhaps? At 45 amps you can be cutting anywhere from 100 IPM for best quality, to 224 IPM for production. I'd probably slow down and cut at 30 amps.

If you've never seen a flat table cut thin sheet, you'd be amazed at the heat control you can get with water. I can hold detail that blows me away sometimes using water to cool the metal being cut. The same cut without water, melts away.

Perhaps a small removable water box/tray that holds the bottom half of the tube in water as it rotates it transfers heat away?
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Old 11-13-2015, 06:55 PM
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Does anyone know on a hyperthurm powermax 45 mechanized if I could put a powermax 30 torch on it?

.
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Old 11-14-2015, 06:24 PM
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The issue then is heat retention in the material.
You need a way to get rid of the heat.
A water bath as suggested I can see working but not in the tube/Dragon application.
You could go to a mist of water sprayed side opposite of the torch.
That would kill heat fast as would a spray of any compressed gas the closer to liquid the better.
You might even just go with Compressed air blowing from cold to hot 180 from the torch... As long as that doesn't mess with the torch.

https://www.vortec.com/c-9-cold-air-guns.aspx

E
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Old 11-16-2015, 09:20 AM
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Quote:
Originally Posted by JaysinSpaceman View Post
The single biggest difference that I made when cutting AL (other then the correct travel speed) was putting in a refrigerant dryer. No matter what I did before I always had an ugly cut with lots of spiky dross. Now I have very nice cuts with little dross to clean up. Someone told me that you can also go to straight nitrogen but I don't know what's involved or the cost. Harbor Freight has a knock off air dryer that has great reviews and is only $3-400.

Thanx,
Jaysin
On the refrigerated dryer, what cfm is it?
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Old 11-16-2015, 01:08 PM
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21.6 cfm. My Hypertherm Powermax 1000 needs 6.7 cfm air so it should be more then enough for the powermax 45.

Link

Hope that helps.

Jaysin
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Old 11-16-2015, 01:26 PM
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Quote:
Originally Posted by JaysinSpaceman View Post
21.6 cfm. My Hypertherm Powermax 1000 needs 6.7 cfm air so it should be more then enough for the powermax 45.

Link

Hope that helps.

Jaysin
This is a dryer and doesn't appear to be a refrigerated dryer. Am I missing something?
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  #14  
Old 11-16-2015, 01:54 PM
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Quote:
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This is a dryer and doesn't appear to be a refrigerated dryer. Am I missing something?
Never-mind, I see where you came up with the refrigeration
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