Best Practices for Handling a Plasma Cutting Torch

Plasma cutting is one of several popular methods for cutting metal. It is a versatile and efficient process that uses high-temperature plasma to melt through electrically conductive materials. However, mastering the art of plasma cutting requires a thorough understanding of the technology, proper techniques, and adherence to safety guidelines.

In this blog post, we will delve into the best practices for handling a plasma cutting torch, ensuring both safety and efficiency in your cutting endeavors. We’ll also explore when it might be time to upgrade your operation with a CNC plasma cutting machine, unlocking even greater levels of precision, speed, and productivity.

Wear Proper Protective Equipment (PPE)

Handling a plasma cutting torch requires strict adherence to safety protocols, starting with wearing the right protective gear. Everyone using this machinery should wear the following:

Eye Protection

Plasma arcs emit intense UV and infrared radiation, so a welding helmet or safety glasses with side shields is necessary. Using a shade 8 to 12 lens is essential to protect your eyes. Auto-darkening helmets are highly recommended as they automatically adjust the lens shade when the arc is struck.

Hand Protection

Thick, insulated welding gloves protect your hands from heat, sparks, and sharp edges. Ensure they are in good condition, free of holes or tears.

Body Protection

Wear long-sleeved shirts and pants made from flame-resistant materials like leather or treated cotton. Avoid synthetic fabrics that can melt and stick to your skin in case of sparks or splatter.

Hearing Protection

Plasma cutting can be noisy, so wear earplugs or earmuffs to prevent hearing damage.

Respiratory Protection

Depending on the material being cut and the ventilation in your workspace, a respirator may be necessary to filter out fumes and dust particles. Consult the material safety data sheet (MSDS) for specific recommendations.

Proper Footwear

Steel-toed boots protect your feet from falling debris and accidental contact with hot metal.

While welding and cutting are different processes, they often require the same safety gear since both involve bright sparks and intense heat. Failing to wear proper protective equipment increases the risk of burns and eye injuries.

Inspect your gear for signs of wear—cracks, fraying, tears—before each use. Damage to safety equipment can put you at risk and may break OSHA laws.

Pro Tip

When choosing welding gloves for plasma cutting, prioritize heat and flame resistance, durability, and dexterity. Look for gloves made from high-quality leather with reinforced stitching, like Kevlar. Ensure a snug fit for optimal control and comfort, and consider features like long cuffs for added protection.

Maintain a Clean Work Environment

A clean workspace is essential for safe and efficient plasma cutting. Flammable materials, debris, and clutter hinder your ability to work efficiently and increase the risk of accidents, such as spark-caused fires. Have a fire extinguisher readily available in case of fire.

Additionally, your workshop should have adequate ventilation, as plasma cutting produces fumes that can be harmful when inhaled. Consider using a fume extraction system to remove the fumes and maintain clean air.

Inspect the Equipment

Before operating your plasma cutter torch, thoroughly inspect the equipment to verify it’s in good working order. Examine consumables such as nozzles and electrodes for signs of wear or damage, as worn parts can degrade the quality of your cuts and create operational inefficiencies.  

Check the hoses and connections for leaks or cracks, which could present safety hazards or hinder optimal functioning. Tighten loose fittings properly, but avoid overtightening, which may damage components.

Keep the Torch Clean

Inspect the torch head for debris or buildup before each use, and wipe it down after every cut. Obstructions can affect the quality of your cuts and may also pose a safety risk. Use a lint-free cloth to clean the torch head, and avoid using solvents or abrasive cleaners, which can cause damage.

Cleaning the torch between uses is vital to its longevity since slag, metal debris, and residue may otherwise accumulate on the nozzle and other components. This can obstruct the flow of the plasma arc, reducing cutting accuracy.

Practice the Correct Cutting Technique

First, secure your workpiece. Ensure the metal you’re cutting is properly secured to prevent movement during the cutting process. Clamps or a heavy, stable work surface are essential.

Next, ensure proper grounding. Before starting the plasma cutter, ensure it is correctly grounded to prevent electrical shock.

Start each cut with the torch at a 90-degree angle to the material unless your specific cutting application demands otherwise. This positioning allows for the cleanest penetration and minimizes uneven edges on the cut surface.

As you cut the metal or other material, keep your hand steady, and hold the torch consistently. Sudden movements or inconsistencies in your grip can result in jagged or off-center cuts, which may require you to start over.

Never touch the torch tip or workpiece while it is hot. Allow the torch and workpiece to cool down completely before handling them.

Pro Tip

When starting a cut in the middle of a plate, use a piercing technique to avoid damaging the torch. Hold the torch at a 45-degree angle, then slowly bring it to vertical once the arc has pierced the material.

Adjust the Travel Speed for Material Thickness

Another best practice for handling a plasma cutter torch is to adjust the travel speed according to the thickness of the cut material. Generally, thicker materials require a slower travel speed for proper heat and cutting action. A faster travel speed may be necessary for thinner materials to prevent overheating and warping.

Avoid Dragging the Torch

Allowing the torch tip to drag across the surface of the material damages the nozzle and compromises the precision of your cuts. To prevent this, hold the torch slightly above the material during operation. If your cutting technique requires constant contact, consider using a drag shield to protect the nozzle while maintaining consistent spacing.

Follow the Manufacturer’s Manual

The manufacturer’s manual contains crucial details about your plasma cutter model’s proper operation and maintenance. Once you buy the equipment, carefully read the manual, and educate all operators on its proper use. Often, the manufacturer’s manual will detail information on the following:

Gas Flow

Proper gas flow regulation is essential for achieving precise cuts and ensuring the torch stays cool during operation. Before using the tool for the first time, read through the manufacturer’s recommended settings for gas pressure. Incorrect pressure can lead to inconsistent cuts or damage to the material you’re working with.

Maintenance Schedule

The manufacturer’s manual should outline how and when you should tend to specific care tasks. Note this information on a calendar to keep up with the machine’s required maintenance.

Troubleshooting

Your plasma cutter may not always function as expected. In these situations, refer to the manufacturer’s manual for troubleshooting tips, or contact customer support for assistance. Ignoring warning signs or attempting to fix issues without proper knowledge can lead to further damage and potential safety hazards.

Seek Professional Assistance

As a metal fabricator, various customers go to you for their cutting needs; similarly, you should turn to machine manufacturers for technical assistance. Contact customer support if you encounter an issue, and if the manual doesn’t have the answers you need.

Trying to fix complex issues without professional help can lead to costly mistakes, downtime, and potential safety risks. A reputable manufacturer will have a team of experts ready to assist you in achieving optimal results with your plasma cutter torch.

The Case for Upgrading to a CNC Plasma Cutting Table

While handheld plasma cutting torches are versatile and cost-effective, CNC plasma cutting tables offer significant advantages for those seeking higher precision, efficiency, and productivity. Here’s why you might consider an upgrade:

Enhanced Precision and Accuracy

CNC systems use computer-guided motion to achieve extremely precise cuts, far beyond what’s possible with manual operation. This is crucial for intricate designs and parts that require tight tolerances.

Increased Productivity

CNC tables can cut much faster than handheld torches, significantly reducing production times, especially for complex or repetitive cuts.

Material Efficiency

CNC software can optimize material usage through nesting, arranging multiple parts on a single sheet to minimize waste.

Automation and Reduced Labor Costs

Once programmed, a CNC table can operate with minimal human intervention, freeing up your workforce for other tasks and reducing labor costs.

Buy Quality Plasma Cutting Torches

Quality is essential no matter what type of cutting torch you use. As with any tool, using a plasma cutter torch can be dangerous, especially if you purchase poorly made equipment. Always buy from reputable manufacturers or dealers, and look for reviews and certifications to ensure a high-quality product.

When shopping for a plasma cutter torch, look for experienced brands with positive reviews from other customers. Consider factors such as cutting capacity, consumables compatibility, and support services before making your final selection. Investing in quality equipment upfront pays off in the long run with fewer operational issues and improved productivity.

Shop at Koike Aronson

Koike has over 100 years of experience producing high-quality welding and cutting equipment. Browse our diverse range of plasma cutting machines, including the Koike Aronson plasma table. We’re always happy to help customers if you have any questions or require assistance with their Koike equipment.