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Tool Talk Discussion Forum

Plasma cutter consumables life?

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Butch(OH)

03-03-2008 08:05:49

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I am an old school torch man but got a good deal on a rebuilt Hypertherm plasma cutter. I like the thing for certain work but I question the life I am getting from my "consumable" parts. Since it doesnt run steady I have to quess but if I was to be cutting say 4" channel iron there is a noticeable decrease in the quality of cut after 5-6 cuts from errosion of the tip. After maybe 30 cuts it needs a tip and what ever you call the part inside. It came with several extras so I didnt worry much about it until I priced some replacements, Wow!. Now I am wondering if I should park it or if I have something wrong? What kind of cutting life should I expect out of a tip?

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NcNE

03-03-2008 20:28:59

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Re: Plasma cutter consumables life? in reply to Butch(OH), 03-03-2008 08:05:49

As the others have said on here, clean dry air is a must. I work with an HT 1650 attached to a cnc machine every day. In the past few months, I"ve had a problem with the electrodes prematurely shorting out. Using the 100 amp electordes, running a constant 80 amps with my digital hight control working (3/16" arc length) we could only average 30-40 ft. per electrode. Switched back to the 80 amp electrodes we had from our old 1250 machine and we can average 500 ft. If the dry air and stand-off dont work for you I would suggest letting your supplier know about your problem. Hope this helps. NC

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T_Bone

03-03-2008 22:22:11

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Re: Plasma cutter consumables life? in reply to NcNE, 03-03-2008 20:28:59

Hi NC,

What is the difference in electrodes between the 1650 and 1250?

Have you came up with a reason of why the 80a eletrodes last longer?

Is there a kerf cut difference between the two?

Is the arc distance the same?

Just currious.

T_Bone

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Puddles

03-03-2008 12:58:17

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Re: Plasma cutter consumables life? in reply to Butch(OH), 03-03-2008 08:05:49

Hi Butch, I have a Hypertherm 1250. I also have a cnc plasma cutter so I can give you some actual numbers, being as the computer tracks that for me. At 80-amps I can cut 250-feet, with at least 200-plunges before seeing any abnormalities in the quality of the cut.
I agree with all the others, dry air is a must!
In the 2nd picture you can see my after cooler on the far wall. :o)

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bjw4076

03-03-2008 12:05:58

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Re: Plasma cutter consumables life? in reply to Butch(OH), 03-03-2008 08:05:49

These folks have pretty good prices

Untitled URL Link

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Stan in Oly, WA

03-03-2008 09:38:27

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Re: Plasma cutter consumables life? in reply to Butch(OH), 03-03-2008 08:05:49

Hi Butch,

Drying the air is by far the most important thing you can do to extend the life of your consumables, but you might also squeeze out a little more time by adding a standoff so that the tip never touches the work. I think that the correct distance from the tip to the work is a constant, regardless of the thickness of the metal or the power setting of the machine (if I'm wrong, we'll find out here real soon.) I know that some torches are or were manufactured with built-in standoffs so that all cutting could be done by dragging the torch on the work, so it seems reasonable that equivalent aftermarket products would be available. Or you ought to be able to make something like that fairly easily.

All the best, Stan

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Butch(OH)

03-03-2008 12:19:08

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Re: Plasma cutter consumables life? in reply to Stan in Oly, WA, 03-03-2008 09:38:27

My shop air is clean and dry, epecialy dry this time of year and there is an air drier/filter mounted on the unit. The tips are the contact type with the stand offs built into them, was told to drag it on the work. Power sittings seem to have liitle effect on tip life.

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Oly

03-03-2008 08:18:52

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Re: Plasma cutter consumables life? in reply to Butch(OH), 03-03-2008 08:05:49

Not only dry air is needed but make sure you don"t have a air hose that someone has used with an air nailer. Some carpenters squirt oil in the hose. That really is tough on plasma tips and even heads. I use one of those filters with a toilet paper roll in it just before the machine. I think it is a Hubbel.
For better pricing I have used American Torch out of Florida for several years for consumables. Google them.

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Bob

03-03-2008 08:07:55

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Re: Plasma cutter consumables life? in reply to Butch(OH), 03-03-2008 08:05:49

Just a suggestion... a plasma cutter needs DRY air, or tip life will be further reduced. Do you have an air filter/dryer ahead of it?

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504-2

03-03-2008 18:42:21

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Re: Plasma cutter consumables life? in reply to Bob, 03-03-2008 08:07:55

Butch, There are different tips for different things. Check with your welding supply co, we have a chart hanging on the wall at work I`ll see if I can get a copy. Of course I will have to remember it first (The mind goes first)

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504-2

03-04-2008 17:27:20

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Re: Plasma cutter consumables life? in reply to 504-2, 03-03-2008 18:42:21

Butch, Thermadyne says 40 amps for 1/4 in max. using a drag tip. Over 1/4 in use a stand off tip at 60amps. They also make a drag shielding tip that sets the stand off of you for 70 to 120 amps. Of course if you use their brand they will last longer(it says so in the ad) LOL On the web at, thermal-dynamics.com

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