Plasma Cut Aluminum Edges, Pictures

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Okay there are millions of threads here with pictures of weld beads, a few with pictures of plasma cuts in steel, and next to none that I can find with pictures of plasma cuts in aluminum ( with air, or with argon ).  I'm not happy with the edges I'm getting, and I have read that "with tuning" ( both the machine and the operator ) it is possible to get 'nice' cuts.  I'd like to see some pictures of what is possible, so I can tell how far away I am.  It would also be interesting to see how much difference argon makes.   Anyone want to show off some pictures?   Thanks.__David Hillman
Reply:You should post yours first..I don't have the capability to do that...(Cutting)...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:These were made on 3/16" but I can't remember if with my former Powermax 350 or current Pak Master 100XL.  Cut with compressed air.Nitrogen is typically used to eliminate the need to prep the edge prior to welding and I understand that H-35 (35% hydrogen / 65% argon) is used for thicker SS and aluminum.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:The few times I cut Al with my plasma, it leaves TERRIBLY rough edges. I typically don't mess with adjusting amperage, and leave it on high. Leaves a really crappy saw tooth looking cut behind.I'm sure there is a way to reduce this, but for as little Al that I cut this way, I could care less.If you need a clean cut, keep messing with the settings. Your pics look pretty good compared my cuts!http://jackalopefab.com/MM210Synchrowave 200DXMiller XMT350 w/60series feederMiller Bobcat 250 with SGA 100 and spoolgunHTP PlasmaFull Machine shop with everything
Reply:i got the same results when cutting al with my plasma i just use a circ or table saw when i want straight clean cuts350P 30A spool gun cut master 51  syncro 250 other stuff " take a dog off the street and make him prosper and he will not bite you sad the same cannot be said for man" i didnt use punctuation just to piss you off
Reply:I tried plasma cutter on 1/8" alu sheet & it was just not nice. I've found that a good powerful jig saw with the right blade cuts awesome, just trace & cut whatever shapes you need as easy as if it was wood. clean edges probably not the best for long straight cuts, there I guess I'd look for the right rotary blade too. I really wanted to get good cuts with plasma too but after a while I realized it's just not worth it. it's just too easy to cut with the right blademiller 330a bp TIGmiller dynasty 200DX TIGmillermatic 185 MIGthermal dynamics cutmaster 101 plasma cuttersnap-on YA5550 plasma cutterhypertherm powermax 30 plasma cutterbaileigh CS225 cold sawetc....
Reply:This is some .188 aluminum cut at 60 amps on my cnc table. compressed air only. Attached ImagesEsab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:That's what I'm talkin' about, Brand X.  Are those with the TD in your signature?    Mine look a lot more like Duane's...   1/8th 6061... cut with Cutmaster 38 at 25 amps.   Same cut after dragging a file along the bottom edge...   Here's a 1/4", same cutter at 30 amps.   And after removing the dross with a quick file swipe or two...__David Hillman
Reply:Cutmaster 151  I was not getting really good cut edges until I turned the amps up to 60. I had a 38 XL (TD) with a SL-60 torch, and it was a 29 amp machine. I don't think I was all that impressed on anything 1/8 and above. On 16 ga. it was pretty good. I know the little 11 amp esab would cut  16 ga. like a laser. Esab's are kind of funny, that the old torch designs excel on aluminum. I was surprised how well a 500i would cut .500 aluminum. (35 amp machine) Surprised it cut through it.Maybe try cutting a different type of aluminum ? (5052)Last edited by Brand X; 10-20-2011 at 01:20 AM.Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:3/16" aluminum....I have done hundreds of these parts.....which are used on a zipline trolley. Nice edge, good accuracy, just a little fuzzy dross on the bottom that wipes off with a finger.Aluminum cutting with an air plasma is strictly a thermal process, as the material does not easily oxidize like steel does. Steel cutting takes advantage of the thermal (melting) capability of the plasma, as well as an exothermic reaction from the oxygen content in air.Here are a few pics of my cuts....done with a Hypertherm Powermax45 at 45 amps. The fiest is .090" aluminum, the other two are 3/16".Jim Colt Originally Posted by David HillmanOkay there are millions of threads here with pictures of weld beads, a few with pictures of plasma cuts in steel, and next to none that I can find with pictures of plasma cuts in aluminum ( with air, or with argon ).  I'm not happy with the edges I'm getting, and I have read that "with tuning" ( both the machine and the operator ) it is possible to get 'nice' cuts.  I'd like to see some pictures of what is possible, so I can tell how far away I am.  It would also be interesting to see how much difference argon makes.   Anyone want to show off some pictures?   Thanks.
Reply:Originally Posted by Brand XCutmaster 151  I was not getting really good cut edges until I turned the amps up to 60.
Reply:Originally Posted by forhireThose are some nice cuts in aluminum. I have the same plasma cutter on my cnc. What kind of inches per minute are you going? You mentioned 500 ipm with the 0.50", am I to assume the same for the thinner material.
Reply:On the .188 aluminum cut at 60 amps, it was 66 IPM On .250 aluminum cut at 80 amps, it was 105 IPM.Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:.189 Alu, 40 amps, CUTMASTER A-120.  Cut speed and torch height make a big difference in cut quality on this material.  HAnd cutting will be better if you drag cut up to 1/4 inch. Attached Images