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School Me On Plasma Cutters!

ARAMP1

ARAMP1

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Okay, I want to start out by saying that I'm a pretty brand loyal guy. Once I try and like something, I'll go back to the brand for another item first be it Snap On tools, Levi jeans, Fender guitars, or Marshall amplifiers. Anyway, I'm a HUGE Lincoln fan. I've always had Lincoln welders and my most recent TIG is amazing. I'll never be good enough to use it to it's full potential, and the quality is there, so I'll be able to use it for the rest of my life.

Anyway, I've been getting tired of using a wheel to cut my metal and looking at Lincoln plasma cutters. I about bought a small 20 amp unit before my friend stopped me. He basically explained that bigger was better and told me to take his Miller 40 amp.

Plasma-1.jpg


I've been googling reviews and reading a lot of this one is better than this other one. Then I go and research the machine and it's 440V 3 phase power...of course it's going to cut through everything!

Anyway, I'm just wanting to get some pointers on what to look for. I'd say I'd be mainly cutting 1/4" to 3/16" maybe up to 3/8".

I've been wondering around my garage just cutting stuff with my buddy's Miller. It's awesome.
 
A 220V input 40A output unit is a good compromise. Not necessarily needed for the home auto shop, but the cut speed is so much faster it's ridiculous, not to mention piercing is much better with more power. Also, get one with gouging capability. I use that just as much or more than the cutting tips. I have a Miller 625 Xtreme and love it. Very small and portable, yet very powerful. Only weights 21 lbs and comes with a carrying case. Looks like a lunch box when you take it out of the case. The cables take up more room than the unit itself.

http://www.millerwelds.com/products/plasma/product.php?model=M00243

You can get them for less than $1500 if you get a deal.

Another good brand of plasmas is Hypertherm. The powermax 45 I've heard is an excellent unit comparable to that one.
 
Also when sizing one for your needs, remember that as long as you get used to your machine and know what you are doing you can easily cut 1-2 sizes thicker steel than they advertise. We had a 240/480 single phase unit in the fab shop I used to work in. It was rated at 1/2" but I regularily cut 3/4" with it. some long straight clean ones. I beleive ours was a hobart but dont quote me on that:dunno: I know it was the same grey and had red letters. I know that a good plasma is one of the handiest tools to have though :thumb:
 
I just bought myself a Miller 375 Xtreme and I love that little thing! My shop's power ain't quite good enough to run it (lots of line losses from the house to the shop, only 90V out back there sometimes...) but if I have anything bigger to cut I just pull the 5000W generate out and it runs it just fine at max power.

It was extremely useful when I cut my IFS out of the Tahoe, and I can see myself using for a lot more applications than that.
 
Wow, you guys have had some different experiences with plasma cutters than I have.

I find they are usually over rated for what their actual capacity is. Maybe I see it different on the automated side. :dunno:
 
the automated ones may move too fast:dunno: When i cut the 3/4" I went real slow and angled it very slightly back. slow as in about 5-6 minutes to makean 18" or so cut. I havent ever used an automated one. but theres no substitute for a good handheld plasma cutter. way more uses than intended too.
 
shady said:
the automated ones may move too fast:dunno: When i cut the 3/4" I went real slow and angled it very slightly back. slow as in about 5-6 minutes to makean 18" or so cut. I havent ever used an automated one. but theres no substitute for a good handheld plasma cutter. way more uses than intended too.
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Automated, you can control the cut speed down to inches per minute. Infinitely controllable.

I think you may be refering to what is consider "Sever" capacity. In otherwords, it will make the cut but the quality is low enough they don't consider it a true "cut" any longer.

Some manufacturers have several different ratings for each machine, Cut, Sever and one more but I can't remember the terminology.
 
I dont know wich it was, It just said 1/2" on the front:rolleyes: the cut through 3/4 I did came out nearly like a cutoff wheel would do though. I hit it with a grinder to take off the rough edges and that was it. :thumb:
 
cybrfire said:
Automated, you can control the cut speed down to inches per minute. Infinitely controllable.

I think you may be refering to what is consider "Sever" capacity. In otherwords, it will make the cut but the quality is low enough they don't consider it a true "cut" any longer.

Some manufacturers have several different ratings for each machine, Cut, Sever and one more but I can't remember the terminology.
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You're probably htinking of the "pierce" rating. Which is how thick it can pierce through without starting on an outside edge, for holes and such. Very handy to do that as well. I make lightening holes with mine. I use some particle board as a template along with the drag tip.
 
Well, I've been using my buddy's miller for a couple days now and it's great, but I can't for the life of me cut a straight line. I use a straight edge when I can, but some times, you just can't get one in there. :doah:
 
ARAMP1 said:
Well, I've been using my buddy's miller for a couple days now and it's great, but I can't for the life of me cut a straight line. I use a straight edge when I can, but some times, you just can't get one in there. :doah:
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Yep, clamp a metal ruler down and use a drag tip. Or they make an attachment that has little roller wheels to help keep it straight. But other than that, grinding wheels and flap discs are used to make it look nice after the cut.
 
I usually use a 2x2 pc of angle iron for a straight edge, the thicker the better, as the thinner gauges tend to have some bend in them and are not always straight. If your cut is fairly long use clamps at each end. Brand wise we have Hypertherm and Thermal Dynamics at our shop, both quality machines. I have always liked Miller products but have not used their plasma cutters. That being said I would imagine both Miller machines cited would do fine for your application.
 
I run a Hypertherm Powermax 900. 55 amps. It'll do 3/4" without breaking a sweat...nice clean cuts. Sever capacity up around 1"+. Great machine, picked up used off ebay years ago. I have experience with pretty much every brand out there- Hypertherm, Miller, Lincoln, Thermal Dynamics, Esab, Hobart etc.... That said, as far as plasma cutters go, my favorites and the only brands I'll ever own are the Hypertherms and Thermal Dynamics. :pimp:
 
i couldn't afford the big name machines, nor could i justify the price for just home/ hobby use. i bought a parker a couple years ago when they were really promoting them on here and pirates. it's worked very well for me. the 40A rips through sheet metal like warm butter. i've cut up to 1/4" and was very happy w/ how little clean up it took.

http://parkermetalworking.com/parkermp100223_002.htm
 
folkenheath said:
You're probably htinking of the "pierce" rating. Which is how thick it can pierce through without starting on an outside edge, for holes and such. Very handy to do that as well. I make lightening holes with mine. I use some particle board as a template along with the drag tip.
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Yes, the pierce rating is also different than the actual cut rating.

Take a look at how this Hypertherm is rated.

https://www.hypertherm.com/en/Products/Handheld_Plasma/Systems/powermax85.jsp

they have a rating for "cut" and a rating for "severance." Then seperately a "pierce" rating.

Pierce rating is always the lowest dimensional thickness followed by cut then severance. I don't know how they determine what is good enough and what isn't. I do believe there is a standard though.
 
Okay, what's the deal with cutting aluminum? Do you need anything special for it? I tried to cut some 1" thick aluminum and figured it'd go through it like butter. It didn't.
 
cybrfire said:
Aluminum has always cut pretty well for me. Did yours come with a manual for the settings for aluminum?

Here's a nice link.

http://www.youtube.com/watch?v=KCjrI4EZSE0&feature=related

These guys must be on a suicide mission.
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I'm just borrowing this one from my buddy until I find one for myself, so no manual. I wonder if I had the air pressure or amps too high. It just melted the aluminum into a blob. Didn't really cut it.

Not too sure I would have put my hand out there while it was still cutting. :eek1:
 
ARAMP1 said:
I'm just borrowing this one from my buddy until I find one for myself, so no manual. I wonder if I had the air pressure or amps too high. It just melted the aluminum into a blob. Didn't really cut it.

Not too sure I would have put my hand out there while it was still cutting. :eek1:
Click to expand...

That does sound odd.

In that video they are cutting aluminum over water which by many is considered an explosion hazard. The aluminum dross pulls oxygen out of the water which leaves you with free hydrogen. Usually not a problem but it can build if you have a pocket build up under the sheet. Course then you rip across it with the arc and kaboom.
 
not to hijack, but have you ever tried to cut brass w/ a plasma? i have a friend who cracked a cymbal. it's not at the edge where they normally crack and it can be cut out w/ a cutoff wheel. this one cracked in the middle. i was wondering if i could cut an oval out w/ the plasma.
 
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