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Plasma Cutting Process: Plasma Arc Associated With Arc Constriction Resulting in Higher Ionisation Level in Arc

The plasma cutting process uses a plasma torch to cut electrically conductive materials. A plasma torch directs a stream of ionized gas at high speed towards the material, transferring enough heat and momentum to melt and blast away the material. Plasma cutting can cut all types of metals and some non-metals, with a clean cut and minimal heat affected zone. It has advantages over oxy-fuel cutting in terms of speed, precision of cut, and ability to cut thicker materials and in any position. However, it requires more expensive equipment and safety precautions due to hazards such as fumes, noise, radiation, and electric shock.

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234 views27 pages

Plasma Cutting Process: Plasma Arc Associated With Arc Constriction Resulting in Higher Ionisation Level in Arc

The plasma cutting process uses a plasma torch to cut electrically conductive materials. A plasma torch directs a stream of ionized gas at high speed towards the material, transferring enough heat and momentum to melt and blast away the material. Plasma cutting can cut all types of metals and some non-metals, with a clean cut and minimal heat affected zone. It has advantages over oxy-fuel cutting in terms of speed, precision of cut, and ability to cut thicker materials and in any position. However, it requires more expensive equipment and safety precautions due to hazards such as fumes, noise, radiation, and electric shock.

Uploaded by

0502ravi
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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PLASMA CUTTING PROCESS

PLASMA ARC ASSOCIATED WITH


ARC CONSTRICTION RESULTING IN HIGHER
IONISATION LEVEL IN ARC.
RECOMBINATION OF IONS & ELECTRONS RESULT
IN HIGH HEAT LIBERATION.

CUTTING IS DUE TO VAPORISATION PLUS
BLASTING OF MOLTEN MATERIAL.

HIGH TEMP DEVELOPED IN PLASMA JET. ABOVE
10,000 K WITH NITROGEN.

HIGH KINETIC ENERGY IN THE PLASMA JET. JET
SPEED IS MORE THAN 1000 MPH
PRINCIPLE OF PLASMA ARC CUTTING
OXY FUEL v/s PLASMA CUTTING
KERF FORMATION MECHANISM IN
PLASMA ARC CUTTING
I- MELTING BY HEAT
FLUX FROM ARC
COLUMN
II- MELTING BY
ANODE / CATHODE
ENERGY
III-MELTED BY HEAT
FROM HIGH TEMP.
& HIGH VELOCITY
PLASMA STREAM
ADVANTAGES OF PLASMA CUTTING
Possess very high temperature and high
kinetic energy.
Can cut all known metals and non metals both
straight and contour profile cutting.
Cuts are very clean forms little or no dross or
slag.
Heat affected zone is minimum
High speed piercing and cutting is achieved
Piled plate cutting is possible, ever with
different materials.
Cutting possible in all positions & locations
(even under water also)
DISADVANTAGES OF PLASMA CUTTING
(AS COMPARED TO OXY-ACETYLENE CUTTING )
HIGHER INITIAL SET UP COST

MORE SKILLED OPERATOR
REQUIREMENT

MORE SAFETY HAZARDSFUMES, NOISE,
RADIATIONS.

WIDTH OF KERF IS MORE
TYPES OF PLASMA CUTTING SYSTEM
CONSUMABLE ELECTRODE TYPE
CARBON CATHODE
SINGLE OR MULTI PIECE TYPE NOZZLE
WATER OR GAS STABILISED PLASMA

NON CONSUMABLE ELECTRODE TYPE
CONVENTIONAL SINGLE GAS SYSTEM
DUEL FLOW PLASMA SYSTEM
WATER CONSTRUCTED PLASMA SYSTEM
CATHODE MATERIAL - -
Thoriated Tungsten
Zerconium In Copper
Hoffnium In Copper
PLASMA CUTTING GASES
Argon - for reactive materials
Argon + Hydrogen }- for S.S., Al and other
Nitrogen + Hydrogen } non-ferrous metals
Nitrogen + Oxygen - for C.S, cast iron and
18%Ni Maraging steel.
Compressed air - for C.S., S.S and other
materials .

QUALITY OF PLASMA CUT SURFACE
SURFACE SMOOTHNESS

KERF WIDTH

PARALLELISM OF CUT FACES

DROSS FORMATION ON THE BOTTOM
EDGE OF CUT FACES

SHARPNESS OF THE TOP EDGE

DISTORTION
METALLURGICAL ASPECTS OF PLASMA
CUT SURFACE
HEAT AFFECTED ZONE
STRUCTURE CHANGE IN HAZ
(CHROMIUM CARBIDE PRECIPITATION IN SS)
MAGNETIC PERMEABILITY CHANGE IN TYPE
304 STAINLESS STEEL
HARDENING OF CUT SURFACE
INTERNAL STRESSES
AIR ARC PLASMA CUTTING
DUAL FLOW PLASMA ARC CUTTING
WATER INJECTION PLASMA CUTTING
UNDER WATER PLASMA CUTTING
JOB IS SUBMERGED IN
WATER DURING CUTTING
NO METAL FUMES
NO HIGH LEVEL NOISE
AND RADIATION HAZARDS
DURING CUTTING
CUT SURFACE WITHOUT
DISTORTION
PROCESS VARIABLES FOR PLASMA
CUTTING
Torch design - nozzle design & size.
Process variation ( dual gas, water injection etc)
Orifice gas type and flow rate.
Torch stand off distance.
Cutting speed
Cutting power (Voltage and current )
Manual/ mechanised cutting
Material to be cut and its thickness
Quality of cut required rough or smooth
CUTTING SPEED v/s POWER OF PLASMA
SYSTEM
INDUSTRIAL APPLICATION OF
PLASMA CUTTING
SHIPYARDS INDUSTRY
AIRCRAFT INDUSTRY
CHEMICAL INDUSTRY
PETROCHEMICAL INDUSTRY
NUCLEAR INDUSTRY
PRESSURE VESSEL INDUSTRY
DAIRY INDUSTRY
APPLICATION OF PLASMA CUTTING
Straight and shape cutting of all metal and
nonmetals including their oxides, carbides etc.
Cutting of risers and gates in forging and casting
industry.
Stack cutting of several sheets of 1.6mm to 6mm
thickness.
For making holes in thick sections.(Piercing
Operation).
For gouging, applications including pad washing &
rough machining.
For sizing the scrape
SAFETY ASPECTS IN PLASMA CUTTING
GASES AND METAL FUMES:
OZONE (O
3
)
NITROGEN DI-IXUDE (NO
2
)
METAL FUMES
VAPOUR
NOISE : UPTO 120 DB 6 FEET FROM CUTTING
RADIATION : ULTRAVIOLET RADIATION
METAL SPATTER
ELECTRIC SHOCKS
WATER IN PROCESS

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