We collect basic website visitor information on this website and store it in cookies. We also utilize Google Analytics to track page view information to assist us in improving our website.
We collect basic website visitor information on this website and store it in cookies. We also utilize Google Analytics to track page view information to assist us in improving our website.
If you’re passionate about metal cutting or just keen to learn more, you’ve landed in the right place.
For over 38 years, Amber Steel has been at the forefront of metal cutting services, specializing in laser cutting, flame cutting, and plasma cutting. Our expertise has carved a niche in this cutting-edge industry, delivering precision and excellence across industrial projects big and small.
In our blog, we’ll share a mix of useful tips, innovative applications, our thoughts on sustainability in steel cutting, and more. Expect stories from the cutting floor, insights into how our processes can streamline projects across industries, and a few lessons we’ve learned along the way.
While we keep some of our trade secrets under wraps, this blog is designed to offer valuable nuggets of wisdom that you simply won't find anywhere else. Whether you’re a professional in the industry or someone fascinated by the possibilities of metal cutting, you'll find something of value here.
So, stick with us as we delve into the finer points of metal work. We’re glad to share our insights and lead discussions that matter to our industry.
How precision metal cutting propels the aerospace industry, from constructing lighter frames to enhancing aerodynamics.
The role of advanced metal cutting in automotive manufacturing, driving innovations in vehicle design and efficiency.
All about the robust and versatile process of flame cutting, ideal for tackling thicker metals with precision and ease.
Discover the art of crafting metal furniture, where cutting techniques meet design to create both functional and aesthetic pieces.
A behind-the-scenes look at the mechanics of metal cutting technologies and the science that makes them tick.
Laser cutting is where extreme precision meets efficiency, allowing for intricate designs and clean finishes.
The critical role of precise steel cutting in developing reliable and intricate medical devices.
How steel cutting supports the oil and gas industry with components that withstand extreme environments and pressures.
Known for its speed and versatility, plasma cutting slices through conductive metals with hot plasma.
Safety first! Tips and insights on maintaining a safe environment while handling powerful metal cutting equipment.
The backbone of construction, where steel fabrication and cutting technologies create frameworks that shape skylines.
Sustainability
A look at sustainability in metal cutting, focusing on practices that reduce waste and conserve energy to protect our planet.
Plasma cutting is a process that cuts through electrically conductive materials using an accelerated jet of hot plasma. If that sounds like some futuristic technology, you wouldn't necessarily be wrong, even though it's been around for a long time! The evolution of plasma cutting from its history to where it's going is an interesting tale, one the folks at Amber Steel want to explore with you today.
Let’s explore plasma welding history together, starting with some general information:
Plasma cutting is typically used in fabrication settings, automotive repair/restoration, industrial construction, as well as salve and scrapping operations – so to say that it's versatile is an understatement.
Due to the high speed, precise cuts, and the fact that it's generally low-cost, plasma cutting has seen some broad usage over the years, from large-scale industrial computer numerical control (or CNC) applications down to being used for smaller, hobbyist projects.
To understand plasma welding history, you need to understand how the process works. The basic plasma cutting process typically involves creating an electrified channel of extremely hot, electrically ionized gas (i.e. plasma) from the machine itself, through the piece to the cut, creating a completed electric circuit back to the plasma cutting machine through a grounding clamp.
This process is completed by using a compressed gas (oxygen, air, others, etc.), which is blown through a focused nozzle at very high speeds towards the workpiece. Then, an electrical arc is formed within said gas between an electrode near the gas nozzle and the actual workpiece. This creates an electrically charged channel of plasma.
If it sounds like science fiction, we don't blame you.
Electricity from the cutting torch travels down the plasma and delivers high enough heat to melt through the workpiece, while a high-velocity plasma and compressed gas blow the molten metal aside. This is, quite literally, how the machine cuts through the workpiece.
Science. Science and heat.
Plasma cutting is suitable for cutting both thin and thick materials. Hand-held torches can typically cut up to 38 mm (or 1.5 inches) thick steel plates, and stronger, computer-operated torches can cut through steel up to 150 mm (or 6 inches) thick.
Seeing as plasma cutters produce a very hot and localized "cone", if you will, to cut with, they are very useful for cutting through sheet metal into curved or angular shapes.
The arcs of the plasma cutter are generated via a three-step process. Firstly, a high-voltage spark ionizes the air inside the torch head, making the air conductive enough to allow a pilot arc to form. The pilot arc then forms within the torch head along with a current flowing from the electrode to the nozzle inside. The pilot arc burns up the nozzle during this phase.
Secondly, the air blows the plasma out of the nozzle towards the workpiece, providing a curved path from the electrode.
Finally, when the control system senses the current flowing from the electrode to the workpiece, it cuts through the electrical connection to the machine's nozzle. The current flows from this electrode to the workpiece, cutting through the piece without burning up the nozzle.
Plasma cutting was born from plasma welding back in 1957 and was introduced as a very conducive way to cut sheet metal and plates in the 1980s.
Plasma cutting traces its roots to the Second World War, when plasma arc technology was heavily utilized for welding aircraft, vehicles, and armaments. The urgency of wartime manufacturing spurred significant advancements in plasma arc welding techniques during this period.
Plasma cutting had a considerable advantage over traditional metal-on-metal cutting because it didn't produce metal chips. This method provided more accurate cuts and cleaner edges than other methods, such as oxyfuel cutting.
Early versions of the plasma cutting machine were large, slow, and relatively expensive. They were primarily used for repetitive cutting patterns in mass production.
Along with other machining tools, such as CNC, technology was applied to plasma cutting machines in the latter part of the 1980s and 90s. This increased flexibility in plasma cutting machines, enabling them to cut more varied shapes based on instructions programmed into the machine's numerical control board.
These CNC plasma cutting machines did have limitations, however, only capable of cutting patterns and parts in flat sheets of steel using two axes of motion known as X-Y cutting.
There are several methods to start the arc of a plasma cutting machine. For some models, the arc is generated by putting the torch in contact with the workpiece. Other machines, however, utilize a high-voltage, high-frequency circuit to create the arc.
Plasma cutters that work with or are close to sensitive electronics like CNC hardware or computers start the arc in other ways. The nozzle and electrode are typically in contact with one other, with the nozzle acting as the cathode (a negatively charged electrode by which electrons enter an electrical device) and the electrode as an anode (An electrode in a polarized electrical device that allows conventional current to enter). Once the plasma gas begins flowing, the nozzle is blown forward.
Operating plasma-cutting machines requires extensive safety precautions. Even though the machine itself is generally safe to use, those not utilizing the proper plasma cutting safety measures and gear can be at risk of injury. Proper training and equipment are still required.
Proper eye protection and face shields are required to prevent serious eye damage (referred to as arc eye) as well as protect them against damage from flying debris. It's recommended that operators use green lenses to protect their eyes.
OSHA recommends using a shade 8 filter for arc currents under 300 A, noting that lighter filters may be suitable when the arc is obscured by the workpiece based on experience.
It's also recommended that operators wear leather gloves, an apron, as well as a jacket to prevent burns caused by sparks and hot metal.
To avoid potentially catastrophic accidents, it's imperative to work in a clean area free of flammable fluids, materials, and gases. Sparks and hot metal from the plasma cutter can easily cause fires if they're not isolated from potentially flammable materials.
Plasma cutters can shoot hot sparks up to several feet away, and most operators won't realize a fire has started because their face shields essentially blind them to possible accidents.
Once upon a time, plasma torches were actually quite expensive. Due to this, they were generally found in professional welding shops and private garage practices.
However, modern plasma torches are increasingly affordable, now accessible to many hobbyists for less than $300. While older units may be heavy (yet still portable), newer models with inverter technology are lightweight but can match or even exceed the capabilities of their predecessors.
We've taken you through the history, the functionality, efficiencies, and inefficiencies – now let's quick-fire some facts.
Plasma arc welding is hot – very hot. Like, inconceivably HOT. Depending on the torch being used, including the machine's operational settings, they can reach up to 50,000 degrees Fahrenheit. For some perspective, shielded metal arc welding (SMAW) typically reaches temperatures up to 10,000 degrees Fahrenheit. Needless to say, plasma arc welding is 5x hotter than other conventional welding methods.
The plasma used in plasma arc welding is hot, as we explained. But it's also just as inconceivably FAST. When the plasma exits the torch's nozzle, did you know it reaches a speed comparable to the speed of sound? That's Mach 1 speeds!
Many people tend to assume that plasma arc welding is a liquid, but this isn't really true. In fact, it's more factual to say that it's actually a gas. When the electric current is activated, the plasma gas is ionized, increasing its conductivity. This electrical current can then freely flow through newly ionized gas plasma. Neat, right? Science is fun.
Whether it's cutting-edge projects or niche jobs, the team at Amber Steel are industry experts in the realm of steel cutting through laser, plasma, and flame-cutting technology from as far back as 1986. Servicing the Waterloo Region, our specialized team offers production-ready parts to our customers across several industries from mining, automotive, construction, and technology.
Dedicated to both excellence and sustainability, you can trust that by working with Amber Steel, you’re receiving the top-rated parts required for even the most specialized products. You won’t have to second guess our services – we guarantee that whatever the job, our team can help you find innovative solutions to get the job done. See our contact page for more details.
Plasma cutting is known for its versatility, but is it also affordable?
Plasma cutting is a leading-edge technology that utilizes high cutting speed and minimal post-processing by using electrically conductive materials with an accelerated jet of hot plasma. It also uses consumables, such as electrodes and nozzles, which aid in the process's affordability.
Plasma cutting was developed near the end of the 1950s and was designed for cutting high-alloy steel and aluminum. It was designed to be used on nearly all metals (due to their chemical composition) that couldn’t be subjected to oxyfuel cutting. Owing to its very high cutting speeds and narrow heat-impacted zone, plasma cutting is used today for cutting even non-alloy and low-alloy steel.
As the experts at Amber Steel, a leader in the metal cutting space, we’ll be breaking down the efficiency and cost savings provided by a plasma cutting method. Let’s explore.
Before we get into the concept of cost-savings, let's explore what plasma cutters are as well as their consumable parts:
Plasma cutters are essential to the metal fabrication industry. By using plasma cutter consumables, a machine can rapidly cut through hundreds of parts an hour with a high degree of efficiency and precision, making it a great cost-saving choice.
Fewer mistakes result in less wasted labour and material. Over time, plasma cutting consumables do wear down due to the excessive heat involved during the actual cutting process but they are generally affordable to replace.
Even though they're an essential part of the fabricating process, plasma consumables are typically overlooked. These consumables are necessary for the safe and rigid operation of your cutting torch. Plasma-cutting consumables are removable pieces that need regular maintenance and replacement.
At the end of the day, the best value you get from plasma cutting depends completely on what is most valuable to YOU.
In general, plasma cutting is a great option because it has many benefits that make it cost-effective. We’ll be exploring the affordability of plasma cutting from process to parts, including the efficiency and cost-effectiveness of consumable parts.
Lucky for you, even some of the best quality plasma cutting consumables are generally very affordable. It’s important that even when you’re looking to save costs, you’re still choosing quality pieces to ensure your work is precise and controlled.
Otherwise, here are some of the key ways plasma cutting consumables are cost-effective overall:
Plasma cutting consumables, such as nozzles, electrodes, and shields, are all designed to withstand high levels of corrosion, which extends their shelf life. This reduces the need to constantly replace the parts and the overall maintenance cost over time.
Plasma cutting is already an efficient process due to its precision and speed. Plasma cutters allow for rapid and accurate cuts with minimal need to waste materials. This efficiency translates into a lower operational cost, as well as minimizing wasted material. Cuts are also completed more quickly compared to other methods.
High-quality consumables produce clean and accurate cuts, which reduces the need for secondary finishing processes post-cut. This doesn’t just save you time, it also reduces the costs associated with additional labour and equipment usage.
Good quality and reliable consumables minimize machine downtime caused by regular replacements and machine maintenance, which improves your overall productivity and efficiency in the long run.
Plasma cutters with quality consumables operate more efficiently, resulting in a reduction in energy costs than other more costly cutting methods. This means you’ll have lower energy bills and operational costs. That’s a win-win.
When it comes to considering the cost per cut, plasma cutting with quality consumables can be very economical in comparison to other methods, especially if you’re operating in a high-volume production work environment.
Moving away just from consumables, there are multiple other reasons why plasma cutting is a cost-effective and efficient means of metal cutting. If you’re looking to break into the industry, there are some money-saving considerations you need to bear in mind.
An important factor to consider when it comes to making the shift to plasma cutting is the initial upfront investment. CNC plasma cutters generally come at a lower price, followed closely by waterjet cutters, and then finally laser cutters which (despite being an excellent option) are the most expensive.
If you add up the cost of operation such as gas, consumables, power, routine maintenance, plasma cutting operation comes in at a lower cost than other CNC machines. Saving on operating costs is one of the key ways to maximize your output while keeping yourself on budget.
CNC plasma cutters are well-known for being relatively user-friendly. However, they still require training to ensure that the machine operates not just properly, but efficiently. This saves time and money.
A good business practice requires you to calculate the rate of production because your total cost per consumable is going to be determined by the labour cost to run the machine, divided by the number of parts you produce every hour.
Plasma cutting steel beats out the rest in terms of cutting speed because they’re able to cut materials anywhere between 60-500 IPM (inches per minute), increasing your overall rate of production.
The quicker you supply the product, the greater efficiency, and the greater the profit. Laser cutting is renowned for being precise, but it is slower by comparison, while waterjet machines tend to be the slowest out of the three options. Taking this into consideration can help you determine your cost-savings and profitability.
Plasma cutters utilize nitrogen, which means they’re able to cut various materials precisely at varying thicknesses. Plasma cutters produce a high temperature, localized “cone” for cutting through materials. This process is ideal for cutting sheet metal into various angled or even curved shapes. Plasma cutters are also able to cut through metals that have reflective surfaces.
Typical materials cut with a plasma cutter range from steel, stainless steel, brass, copper, and aluminum. You’ll often see plasma cutters utilized in fabrication shops, automotive repair and restoration, industrial construction, and scrapping/salvaging operations, making it an extremely versatile machine.
While it’s true that plasma cutters utilize high temperatures, the systems can keep the surface of the metal cool, eliminating the possibility of material warping. This means you can have clean, high-quality cuts without the risk of ruining the material. Plasma cutters also only use a localized heat zone (the alternative to this is a wide heat-affected zone, or HAZ), that has the potential to burn or melt the material.
Plasma cutting utilizes a less flammable gas, eliminating many of the safety hazards associated with gas cutting. Plasma cutting subsequently doesn’t just cut down on labour costs, but it’s safe to operate with the proper training and improves the quality of your product. All without having to skimp on safety.
Metal fabrication comes with many applications and tools to maximize your cost-effectiveness and efficiency, but plasma-cutting consumables and cutters are a great option for those looking to break into the industry.
Whether you’re looking to buy a machine and consumable parts or are looking to have a fabricator take on your next plasma-cutting project, hopefully, this guide has provided you with the insight you need to make an informed decision.
For more information on plasma cutting and other forms of metal cutting, see our comprehensive blog on Amber Steel’s website.
