Plasma cutting tables are a major investment that can streamline your workflow and skyrocket your productivity. However, maintaining your equipment can be tricky. Your 80 amp plasma cutting table requires the right consumables to achieve clean, precise cuts and ensure the longevity of your machinery.
Plasma cutting relies on a combination of gases, nozzles, electrodes, and other important components to help optimize your performance, minimize downtime, and extend the life of your cutting tools. Understanding what consumables are required for an 80 amp plasma cutting table can help ensure that your cutting table continues to work as expected.
At Hornet Cutting Systems, we manufacture all types of cutting tables, from CNC plasma and laser to water jet and oxy-fuel. We understand the importance of maintaining these machines, which includes regularly inspecting and replacing the consumables in plasma cutters.
Learn more about what consumables are used for an 80 amp plasma cutting table and how Hornet can connect you with the right cutting table for you.
Reasons Why You’re Frequently Replacing Your Consumables
If you find yourself constantly replacing the consumables in your plasma cutting table, it may be due to user error or other reasons. Some of the most common reasons why you need to frequently replace your consumables include the following:
Wrong Timing
Some operators choose to replace their consumables on a set schedule, such as after a certain number of pierces or during specific shift changes. While this approach can be somewhat reliable if you only cut the same metals and thicknesses, varying applications can cause your consumables to wear at different rates. It’s important to visually inspect the consumables to determine if replacement is necessary.
Replacing All Consumables at Once
Not all consumables wear out at the same time. The electrode and plasma nozzle tend to wear out quicker than other consumables, meaning they will generally need to be replaced more often. The electrode and nozzle are directly involved in creating and focusing the cutting arc. If you fail to replace these important consumables, it may affect your cut quality.
When it is time to replace your consumables, count on Hornet to get the job done right. Our Hornet Protection Plus Consumable Loyalty Program allows members to enjoy exclusive discounts on parts, services, maintenance, and consumables. Ask about our escalating tiers of discounts on preventative maintenance performed by our trained staff of technicians.
Improper Gas Flow
In the torch, gas is circulated to prevent the nozzle from melting due to exposure to high temperatures. However, if there is low gas flow in the plasma tool, the nozzle can suffer from premature failure. If you find that your nozzle is constantly burning up, check the gas flow to ensure the levels are adequate.
Improper Pierce Height
Another reason why your consumables may require constant replacing is due to improper pierce height. The distance between the plate and nozzle can directly impact the life of your consumables. When the distance is too high, a misfire can occur that reduces the electrode life. Too low and the plate can suffer damage.
Poor Work Cable Connection
Having a good electrical connection when using your plasma cutting table is critical. With a solid connection, the arc transfer will generally occur within 100 milliseconds. However, a poor connection can result in a ½ second or more delay, which can lead to frequent misfiring and excessive wear on the consumables.
To ensure that your cutting table is running at full capacity, speak with Hornet about our retrofitting services, Retrofitting is an excellent way to modernize your plasma cutting table with the latest innovations and technologies at a fraction of the price of a new machine. If you are in the market for a new plasma cutting table, you can save tens of thousands on a used cutting table.
Types of Consumables Used for an 80 Amp Plasma Cutter
Each consumable in a plasma cutting table plays an essential role in its precision and overall performance. The primary types of consumables used in an 80 amp plasma cutting table include:
Electrodes
The electrode in a plasma cutting table is a copper component that conducts electrical currents from the torch to the nozzle. This consumable is known to have the highest rate of wear and typically needs to be replaced within just a few normal operating hours. Electrodes contain hafnium, which is needed to start the arc and keep it centered on the nozzle orifice.
Swirl Rings
Swirl rings are components that help regulate gas and plasma flow during the cutting process. Due to their exposure to high temperatures, swirl rings must be constructed of highly resilient materials, such as ceramic or volcanic ash. The swirl ring’s function is to swirl the gas in a clockwise rotation. Counter-clockwise swirl rings are also available to help with mirror cutting.
Nozzles
Plasma nozzles help direct the plasma jet to the material, usually metal, being cut. They work by constricting the gas stream through the orifice of the nozzle’s center which helps focus the arc. Improper or worn-out nozzles can negatively impact the size or edges of the part. Plasma nozzles can be found in a variety of materials, such as brass and copper.
Retaining Caps
The retaining cap in a plasma cutting table is the largest type of consumable. It is responsible for holding the nozzle, swirl ring, and electrode in their proper places within the cutting torch. Like the other consumables, the retaining cap must resist high temperatures and is therefore made of a heat-resistant material like copper. A damaged or improper retaining cap can result in gas errors, coolant leaks, and poor cut quality.
Shields
As the name suggests, a plasma shield helps protect all of the other consumables from molten metal and sparks. The shield threads onto the retaining cap at the front of the torch and is usually constructed of ceramic, copper, or another high-temperature material. Using a damaged or the wrong plasma shield can lead to irregular bevel issues and poor cut quality.
Tips to Maintain Your 80 Amp Plasma Cutting Table Consumables
There are many things you can do to help extend the life of your plasma cutting table consumables, essentially saving time and money. Some tips to remember include the following:
- Perform Regular Inspections: Regularly inspecting your plasma cutting table consumables for wear, debris buildup, or damage can help extend its life. Strive to perform routine checks at the start of each production run.
- Keep All Consumables Clean: Consumables can collect dirt, grease, and metal buildup over time. This debris can clog up the inner retaining cap and swirl ring, causing the arc to become skewed.
- Replace Consumables As Needed: It is inevitable that your consumables will wear out with use. Follow the manufacturer’s recommendations and replace the consumables as needed based on the material being cut and other variables.
- Check the Gas Pressure: Set the plasma gas pressure setting as close to the applicable cutting charts as possible. Also, check the amperage and cutting speed to help prolong the lifespan of your machine’s components.
- Switch to Quality Consumables: Making the switch to higher quality consumables can help elevate your cutting performance and extend the life of your consumables.
- Verify Piercing Height: It can take up to 4.5 seconds for the plasma arc to pierce through the plate. Piercing too close to the plate can result in damage to the shield cap or result in a misfire.
Discuss Your Cutting Table Needs with the Experts at Hornet
Choosing the right consumables for your 80 amp plasma cutting table and replacing your consumables regularly is essential to streamlining your workflow and limiting disruptions caused by machine misfires and similar issues. At Hornet Cutting Systems, our team of cutting table experts can help you find the right cutting table for you or retrofit your current machine to increase your cutting quality and productivity.
Contact Hornet today to discuss your cutting needs or to learn about our wide range of OEM cutting table products, parts, and services.
