Cut Charts And Marking Charts - Plasma Automation

Cut Charts and Marking ChartsWARNINGEXPLOSION HAZARD – CUTTING WITH ALUMINUM NEAR WATERDo not cut aluminum alloys underwater or on a water table unless you can preventthe accumulation of hydrogen gas. Never cut aluminum-lithium alloys in thepresence of water.Aluminum can react with water to produce hydrogen, resulting in a potentiallyexplosive condition that can detonate during plasma cutting operations. Refer to theSafety and Compliance Manual (80669C) for more information.WARNINGEXPLOSION HAZARD – CUTTING WITH FUEL GASESDo not use combustible fuel gases or oxidizing gases with Powermax systems.These gases can result in explosive conditions during plasma cutting operations.WARNINGTOXIC FUMES CAN CAUSE INJURY OR DEATHSome metals, including stainless steel, may release toxic fumes when cut. Make sureyour work site has adequate ventilation to ensure that the air quality level meets alllocal and national standards and regulations. Refer to the Safety and ComplianceManual (80669C) for more information.Powermax45 XPOperator Manual809240121

9Cut Charts and Marking ChartsUsing the cut chartsThe cut charts in this section are intended to provide a good starting point. Adjust the variables in the cutcharts as needed to achieve optimal results for your cutting equipment and environment.Cut charts are provided for each set of mechanized cutting and marking consumables. A consumablediagram with part numbers precedes each cut chart.Cut charts are included for: Cutting mild steel, stainless steel, and aluminum at 45 A with air using shielded consumables Cutting mild steel and stainless steel with air using FineCut consumables Cutting stainless steel at 45 A with F5 using shielded consumables Marking and dimpling at 10 – 25 A with air and argon using Marking consumablesEach cut chart may contain the following information: Amperage setting – The amperage setting at the top of the page applies to all the settings givenon that page. In FineCut charts, the amperage setting for each thickness is included in the cutchart. Material Thickness – Thickness of the workpiece (metal plate being cut). Torch-to-Work Distance – For shielded consumables, the distance between the shield and theworkpiece during cutting. For unshielded consumables, the distance between the nozzle and theworkpiece during cutting. This is also known as cut height. Initial Pierce Height – Distance between the shield (shielded) or the nozzle (unshielded) and theworkpiece when the torch is fired, prior to descending to the cut height. In marking charts, this isreferred to as Initial Marking Height. Pierce Delay Time – Length of time the triggered torch remains stationary at the pierce heightbefore the torch starts the cutting motion. In marking charts, this is referred to as Delay Time. Best Quality Settings (cut speed and voltage) – Settings that provide the starting point forfinding the best cut quality (best angle, least dross, best cut-surface finish). Adjust the speed foryour application and table to obtain the desired result. Production Settings (cut speed and voltage) – 70% to 80% of the maximum speed ratings.These speeds result in the greatest number of cut parts, but not necessarily the best possible cutquality. 122The arc voltage increases as the consumables wear, so the voltage setting mayneed to be increased to maintain the correct torch-to-work distance. SomeCNCs monitor the arc voltage and adjust the torch lifter automatically. Kerf Width – Width of material removed by the cutting process. The kerf widths were obtainedwith the “Best Quality” settings and are for reference only. Differences between installations andmaterial composition may cause actual results to vary from those shown in the tables. Width and Depth – The marking and dimpling cut charts list the profile dimensions of the mark ordimple.809240Operator ManualPowermax45 XP

Cut Charts and Marking Charts9Each cut chart lists hot and cold gas flow rates. Hot flow rate – Plasma is on, the system is operating at running current, and the system is in asteady state at the default system pressure (cutflow, or automatic mode). Cold flow rate – Plasma is off and the system is in a steady state with gas flowing through thetorch at the default system pressure (postflow). Powermax45 XPHypertherm collected the cut chart data under laboratory test conditions usingnew consumables.Operator Manual809240123

9Cut Charts and Marking ChartsMild Steel – 45 A – Air – Shielded220817220854(220953 forohmic orch-to-WorkDistancemmmm234681012162025Initial Pierce Heightmm%PierceDelay Timeseconds0.20.41.53.82500.60.81Edge StartBest Quality SettingsCut 10170110128128128130133136140146152157Production SettingsCut 00240145125127128127130134138141147154Kerf essTorch-to-WorkDistanceinches16 GA14 GA10 GA3/161/43/81/25/83/47/81inches0.06Initial Pierce Heightinches0.15PierceDelay Time%seconds2500.10.20.40.50.60.81Edge StartBest Quality SettingsCut 8128129130136141146151154157Production SettingsCut 125128127127133139141145151154Kerf 20.0860.1030.119Gas flow rate – slpm / scfh151 / 320184 / 390124Hot (cutflow)Cold (postflow)809240Operator ManualPowermax45 XP

Cut Charts and Marking Charts9Stainless Steel – 45 A – Air – Shielded220817220854(220953 forohmic orch-to-WorkDistancemmmm2346810121620Initial Pierce Heightmm3.8%PierceDelay Timeseconds0.10.20.42500.61.54.60.81.2300Edge StartBest Quality SettingsCut 0160126129130131134137141145149Production SettingsCut 20205129128129131134137139142146Kerf hicknessTorch-to-WorkDistanceinchesinches16 GA14 GA10 GA3/161/43/81/25/83/47/8Initial Pierce Heightinches%0.152500.18300PierceDelay Timeseconds0.06Edge Start0.10.20.40.50.60.81.2Best Quality SettingsCut 30131131137142145148151Production SettingsCut 128130131136140142145149Kerf 60.1160.137Gas flow rate – slpm / scfh151 / 320184 / 390Powermax45 XPHot (cutflow)Cold (postflow)Operator Manual809240125

9Cut Charts and Marking ChartsAluminum – 45 A – Air – Shielded220817220854(220953 forohmic orch-to-WorkDistancemmmm23468101216Initial Pierce Heightmm3.8PierceDelay Time%seconds2500.10.20.40.50.60.71.5Edge StartBest Quality SettingsCut 60121130133139139142144152Production SettingsCut 340134129129132136140142148Kerf 1/25/83/4Initial Pierce Heightinches%PierceDelay Timeseconds0.20.152500.40.50.70.06Edge StartBest Quality SettingsCut 137141145152158Production SettingsCut 0132139143148153Kerf 7Gas flow rate – slpm / scfh151 / 320184 / 390126Hot (cutflow)Cold (postflow)809240Operator ManualPowermax45 XP

Cut Charts and Marking Charts9Mild Steel – FineCut – Air – Shielded and Unshielded220955 (deflector)220948 (shield)220854220953 (ohmic)220930220842220857MetricMaterial .5234AmmInitial Pierce Heightmm%Pierce Delay dedCut 019007878787878828384Kerf Widthmm0.70.60.71.21.3EnglishMaterial ThicknessCurrentTorch-to-WorkDistanceinches26 GA24 GA22 GA20 GA18 GA16 GA14 GA12 GA10 GAAinchesInitial Pierce Heightinches%Pierce Delay Timeseconds0.0400.10.060.152500.20.4450.5Best Quality SettingsCut 87878787878828384Kerf 20.051Gas flow rate – slpm / scfh155 / 330215 / 460Powermax45 XPHot (cutflow)Cold (postflow)Operator Manual809240127

9Cut Charts and Marking ChartsStainless Steel – FineCut – Air – Shielded and Unshielded220955 (deflector)220948 (shield)220854220953 (ohmic)220930220842220857MetricMaterial .5234AmmInitial Pierce Heightmm%Pierce Delay dedCut 010506868686870718184Kerf Widthmm0.60.50.61.01.41.5EnglishMaterial ThicknessCurrentTorch-to-WorkDistanceinches26 GA24 GA22 GA20 GA18 GA16 GA14 GA12 GA10 GAAinchesInitial Pierce Heightinches%Pierce Delay Timeseconds0.0400.10.020.084000.20.4450.50.6Best Quality SettingsCut 86868686870708083Kerf 90.055Gas flow rate – slpm / scfh155 / 330215 / 460128Hot (cutflow)Cold (postflow)809240Operator ManualPowermax45 XP

Cut Charts and Marking Charts9Mild Steel – FineCut Low Speed – Air – Shielded and Unshielded220955 (deflector)220948 (shield)220854220953 (ohmic)220930220842220857MetricMaterial 1.5*234AmmInitial Pierce Heightmm%Pierce Delay dedCut 019006968707275767878Kerf Widthmm0.60.80.71.31.5EnglishMaterial ThicknessCurrentTorch-to-WorkDistanceinches26 GA24 GA22 GA20 GA18 GA16 GA*14 GA*12 GA10 GAAinchesInitial Pierce Heightinches%Pierce Delay Timeseconds0.0300.10.06400.091500.20.4450.5Best Quality SettingsCut 06870717375767878Kerf 1Gas flow rate – slpm / scfh155 / 330215 / 460Hot (cutflow)Cold (postflow)* Not a dross-free cut.Powermax45 XPOperator Manual809240129

9Cut Charts and Marking ChartsStainless Steel – FineCut Low Speed – Air – Shielded and Unshielded220955 (deflector)220948 (shield)220854220953 (ohmic)220930220842220857MetricMaterial .5234AmmInitial Pierce Heightmm%seconds0.03040Pierce Delay Time0.52.04000.10.150.40.50.645RecommendedCut 010506969696969698080Kerf Widthmm0.70.60.51.31.41.5EnglishMaterial ThicknessCurrentTorch-to-WorkDistanceinches26 GA24 GA22 GA20 GA18 GA16 GA14 GA12 GA10 GAAinchesInitial Pierce Heightinches%Pierce Delay Timeseconds0.0300.10.02400.084000.20.40.50.645Best Quality SettingsCut 96969696969698080Kerf Widthinches0.0280.0250.0230.0220.0210.0490.055Gas flow rate – slpm / scfh155 / 330215 / 460130Hot (cutflow)Cold (postflow)809240Operator ManualPowermax45 XP

Cut Charts and Marking Charts9Stainless Steel – 45 A – F5 – Shielded220817220854(220953 forohmic orch-to-WorkDistancemmmm46810121.5Initial Pierce Heightmm3.8%PierceDelay Timeseconds0.50.62500.8Edge StartBest Quality SettingsCut 3156Production SettingsCut 47150Kerf o-WorkDistanceinches10 GA3/161/43/81/2inches0.06Initial Pierce Heightinches0.15PierceDelay Time%seconds2500.40.50.60.8Edge StartBest Quality SettingsCut oduction SettingsCut erf Widthinches0.0690.0820.0900.098Gas flow rate – slpm / scfh149 / 315184 / 390 Powermax45 XPHot (cutflow)Cold (postflow)F5 is not recommended for thicknesses less than 3 mm (10 GA).Operator Manual809240131

9Cut Charts and Marking ChartsMarking and Dimpling – Air – Shielded420542220854(220953 forohmic sensing)420415220842220857Mild steelCurrent Torch-to-Work Distance Initial Marking .40.25——Delay TimesecondsMarking Speedmm/min in/minLight marking02540100Heavy marking02540100Dimpling0.05——Arc VoltagevoltsmmWidthinDepth1342.790.11 0.02 0.0011112.790.110.09 0.0035—1.980.0780.25mmin0.01Stainless steelCurrent Torch-to-Work Distance Initial Marking 0.25——Delay TimesecondsMarking Speedmm/min in/minLight marking05080200Heavy marking03175125Dimpling0.05——Arc 0.003—2.030.080.230.009mmin 0.02 0.001AluminumCurrent Torch-to-Work Distance Initial Marking HeightAmminmmin112.50.15.10.2103.20.125——Delay TimesecondsMarking Speedmm/min in/minMarking05080Dimpling0.1—Arc VoltagevoltsWidthDepthmm200980.890.035 0.02 0.001——0.890.035inmmin0.09 0.0035Gas flow rate – slpm / scfh137 / 290141 / 300132Hot (cutflow)Cold (postflow)809240Operator ManualPowermax45 XP

9Cut Charts and Marking ChartsMarking and Dimpling – Argon – Shielded420542220854(220953 forohmic sensing)420415220842220857Mild steelCurrent Torch-to-Work Distance Initial Marking .20.125——Delay TimesecondsMarking Speedmm/min in/minLight marking03175125Heavy marking03175125Dimpling0.2——Arc VoltagevoltsmmWidthDepth441.220.048 0.02 0.001441.220.048 0.02 0.001—0.990.039 0.02 0.001inmminStainless steelCurrent Torch-to-Work Distance Initial Marking 125——Delay TimesecondsMarking Speedmm/min in/minLight marking03175125Heavy marking02540100Dimpling0.2——Arc VoltagevoltsWidthDepthmm461.400.055 0.02 inAluminumCurrent Torch-to-Work Distance Initial Marking y TimesecondsMarking Speedmm/min in/minMarking04445Dimpling0.4—Arc VoltagevoltsWidthDepthmm175420.630.025 0.02 0.001——0.660.026inmmin0.04 0.0015Gas flow rate – slpm / scfh120 / 255123 / 260Powermax45 XPHot (cutflow)Cold (postflow)Operator Manual809240133

Cut Charts and Marking Charts 9 Powermax45 XP Operator Manual 809240 123 Each cut chart lists hot and cold gas flow rates. Hot flow rate – Plasma is on, the system is operating at running current, and the system is in a steady state at the default system pressure (cutflow, or automatic mode).