11 Methods to Extend the Life of Plasma Cutting Machine Consumables

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11 Methods to Extend the Life of Plasma Cutting
Machine Consumables
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Whether you are using the world's best quality
machines and parts, the chances of them getting
damaged someday are 100. Of course, using good
quality parts like esab plasma cutter parts will
provide longevity to the machine parts rather
than average quality parts, but maintenance is
still necessary. People often don't apply for
maintenance because of the higher costs it
requires. But investing in effective methods to
reduce losses is also a cost-saving
method. Here we have some commonly used method
list you can apply to reduce the cost of plasma
consumables as much as possible 1. Use a
Reasonable Cutting Height According to the
guidance of the instruction manual, you should
use a reasonable cutting height. Cutting height
is basically the distance between the cutting
nozzle and the surface of the workpiece. When
perforating, you need to use a value slightly
higher than the perforation height in the
parameter table.
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• Do Not Overload the Nozzle
• Overloading the nozzle or exceeding the operating
  current of the nozzle will damage the nozzle.
  Also, the current intensity should only be 95
  of the working current of the nozzle. For
  instance, the current intensity of a 100A nozzle
  should be set to 95A.
• Ensure the Correct Flow Rate and Air Pressure of
  the Plasma
• The correct flow of plasma and gas pressure are
  very essential to the service life of
  consumables. If the air pressure of the machine
  is too high, then the life of the electrode will
  reduce significantly. And if the air pressure is
  too low, then it will affect the life of the
  nozzle.
• The Thickness of the Perforation Needs to be
  Within the Range of the Machine System
• The cutting machine will not perforate the steel
  plate exceeding the normal working thickness.
  The usual working perforation thickness is half
  of the normal cutting thickness for the machine
  having configuration below 100A. For instance,
  the 100A system is set for cutting 1-inch carbon
  steel, then the working perforates should be 0.5
  inches.

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• Keep the Plasma Gas Dry and Clean
• The plasma system requires dry and clean plasma
  gas to work typically. Dirty gas usually creates
  a problem for the gas compression system. This
  will shorten the service life of consumable parts
  and will also cause severe damage. The testing
  method for the gas quality includes setting the
  cutting torch in the test state and placing a
  mirror under it to consume gas in the cutting
  torch. If the water vapor and mist appear in the
  mirror, then you must find out the reason and
  correct it as soon as possible.
• Start the Cutting from the Edge
• Instead of perforating, you should start cutting
  the materials from the edge as much as possible.
  If you will use edge as the starting point, it
  will help to extend the life of the consumable
  parts. Here, the correct cutting method is to
  directly aim the nozzle at the edge of the
  workpiece before you start the plasma arc.
• Apply Splash-Proof Chemical Paint on the
  Protective Shell
• The splash-proof chemical coating helps in
  reducing the buildup of slag on the protective
  shell. But you need to remove the protective
  shell from the torch before applying
  splash-proof paint.

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• Clear the Gas After Replacing Consumables
• First of all, you need to replace the parts with
  good quality parts like esab replacement parts
  as per requirement for maintaining the quality
  of the final output. Once you replace the
  consumables, you should clear the gas. This is
  necessary for retaining the water and discharging
  the mist from the cut.
• Remove the Slag on the Protective Shell
• Removing the slag on the protective shell of the
  cutting torch frequently is necessary.
  Otherwise, it will create a destructive heavy
  plasma arc.
• Keep the Cutting Torch and Consumable Parts Clean
• Any dirt on the cutting torch or any consumable
  parts will strongly affect the function of the
  plasma system. While replacing consumable parts
• Place the parts on the clean flannel
• Replace consumable parts with quality esab
  replacement parts
• Place the parts on a clean flannel
• Check the connection ribs of the cutting torch
  regularly
• Clean the nozzles and electrode contact surface
  with hydrogen peroxide cleaner

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11. Use Softened Water to Inject the Cutting
Torch Hard water can cause metal impurities to
precipitate on the nozzle ring. And it will
affect the airflow, reduce the torch quality, and
shorten the life of consumable parts. The
primary key to maintain the machine parts is to
invest in good quality parts like the esab
plasma cutter parts. And then you can maintain
them as per your budget and usage. Sourcehttps/
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