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Understanding Plasma Cutting: Working Principle and Advantages

Plasma Cutting, Working Principle and Advantages

Traditionally, artisans used hand-held tools to perform any cuts on electrically conductive materials. That surely sounds seriously dangerous, but this has changed now. The industries are now equipped with high-tech devices to perform this task – the plasma cutting tech. You can cut steel, stainless steel, copper, brass, alloys, etc. The plasma cutting tech can cut through a thin and thick sheet.

We will be discussing what plasma cutting is. What is the right working process? What is the principle behind it? Which gas is perfect for the process? What materials can you actually cut? The process works better with electrically conductive material, and this can seem heavy, but you don’t have to worry because we are here to answer & everything in detail. 

Let’s begin by understanding the basics of plasma cutting and get into the details of other questions.

The basics of plasma cutting

Plasma, the fourth state of matter, is a high-energy, ionized gas made of positively charged ions and free radicals. It is made by heating a gas to a very high temperature. This happens until it reaches a point where electrons are stripped away from atoms. The result is a lively mix of positive ions and free electrons, and that’s what we call plasma. 

What is plasma cutting?

Plasma cutting is a process where plasma uses ionized gasses to cut metals. The gasses are heated at high temperatures and then ejected under high pressure to melt the material. Thus, the material then gets separated from the cut. The technique is cost-effective and requires very simple tools to perform the task. 

Having already briefly gained knowledge about plasma cutting, it is now time to focus on the working principle behind it. 

The working principle of plasma cutting

The core of plasma cutting lies in the transformation of regular gas into a supercharged state called plasma. Then, with great care, this charged plasma is guided to melt and slice through electrically conducting materials. It’s like using a strong force to cut through metal with accuracy, resulting in a neat and effective cutting procedure.

Before you know the stages involved in a notion, you can never fully comprehend it. The steps are written below for you:

Step 1: Plasma torch setup

Out of the list of tools involved in making plasma, the plasma torch is one important tool you need. It has a nozzle, electrode, and a chamber where gas is introduced. This torch transfers inert gases into a high-energy state of matter known as plasma. It is important to have a perfectly designed plasma torch if you wish to have a flawless plasma-cutting process.

Step 2: Gas introduction

To begin with, inert gasses, like nitrogen, oxygen, argon, etc., are assembled. After that, the gasses are introduced into the plasma torch. Moreover, it is important for you to remember that this gas is the medium through which the electric arc will pass.

Step 3: Electric arc

Now that the gas is flowing through the plasma torch, an electric arc is formed. This arc is formed between the torch’s electrode and the nozzle. The main objective of this arc is to be the ignition source for the ionization process.

Step 4: Ionization & plasma formation

Although, we have already explained to you how ionization happens and how a mixture of positively charged ions and free electrons is formed. You also know that this results in the making of plasma. However, you should remember that this is an important step in the entire process. 

Step 5: Plasma arc generation

Once you have the plasma ready, the new ionized gas has now formed the plasma arc. This arc travels through the nozzle of the plasma torch. The main job of the nozzle is to focus and accelerate the plasma. What basically happens is that because of this focus and speed acceleration, a high velocity is created, and an intense stream of plasma is formed.  

Step 6: Material interaction

For the next step, you need to understand that as soon as the plasma arc is about to come in contact with the object/metal piece, it will heat it to its melting point. After that, the magic of ionized gasses will happen. They will, moving at a high speed, blow away the molten metal. There you have it, a perfectly cut material.

Step 7: Control parameters

The entire process seems like a cakewalk, but here is a reminder for you. To achieve the best cutting results, there is a dire need to have precise control over some parameters. You will have to look out for factors like gas rate flow, arc current, torch travel speed, etc., The importance of having a certain amount of control allows you to have an error-free cutting process for specific materials, thickness, quality, etc.,

Types of plasma cutting

It would be very interesting to read about the three types of plasma cutting:

Precision plasma cutting, Types of plasma cutting

Conventional plasma cutting

It is the most basic type of plasma cutting, and the plasma torch used in this process uses a single gas. It is interesting to know that this single gas is responsible for the creation of plasma arcs. However, as compared to other advanced processes, the arc in this one is less focused. In return, there is a broader and less precise cut. 

You must know that this type is practically good for objects where high precision is not critical. You can use it in industries such as shipbuilding, construction, automotive, etc., for cutting thicker material at normal speed.

Precision plasma cutting

Secondly, precision plasma cutting utilizes a more refined and focused plasma arc. You can achieve this by adding a second gas into the process. Often, it is an oxygen-based gas. This dual-gas system improves the arc density. The result is quite optimistic; the cuts have been improved.

This type of plasma cutting is best if you want precise & cleaner cuts. Many industries use it, such as fabrication, metal service centers, machinery manufacturing, etc.; you don’t have to worry about maintaining a balance between speed and cut quality.

High-definition plasma cutting

It is like the superhero in the world of metal cutting. This cutting-edge technology goes above and beyond, using a super-focused plasma arc created through a mix of fancy torch design, better gas control, and more power. The results are even fancier; you will get way smaller cuts and super-precise angles.

It is best suited for tasks that need the utmost precision, like in the aerospace and automotive industries, where every cut needs to be spot-on. It’s particularly awesome at slicing through thin materials and making parts with almost no impact from heat. High-Definition Plasma Cutting is the go-to for intricate and detailed work, making it the superhero of the metal-cutting world.

Materials used for plasma cutting

Obviously, there is a particular list of materials that can go through the plasma cutting process, especially the ones that are electrically conductive. Some of the examples are:


Many people choose steel as their metal for their products. And plasma cutting works wonders on different types of steel, like mild steel, carbon steel, and stainless steel. When it comes to slicing through regular steel, conventional plasma cutting is often used.

But, when you need super precise cuts, especially for fancy stuff like plates, glasses, bowls, etc., you should bring out the big guns, i.e., plasma cutting. It is basically like having every type of tool for every type of steel. 


Aluminum is a light and strong metal used on a daily basis in many things. Well, it is not like you can bend aluminum with your hands to get a plate or a sheet; you will have to use plasma-cutting tech. The reason is simple: it can give you clean & precise sheets, plates, etc.,

The cuts are pretty sharp and clean. For your benefit, the material also stays strong and intact. After all, it is all about using the right tools to make sure you get the job done just right.

Copper & brass

Copper and brass are the shiny metals that bring charm to various things around you. You must have seen copper plates in your kitchen. Well, when it comes to cutting them, plasma cutting is the best. 

And when you’re aiming for precision, especially for those detailed designs, plasma cutting is the master of all. It’s like having a craftsman’s touch to make sure you get those perfect cuts.


As you already know, the alloy is a mixture of metals, and plasma cutting can effortlessly cut through it. You can cut through alloy materials like tool steel, nickel alloys, and even fancy titanium alloys with precision and ease. It’s like having the best tool that adapts to whatever mix of metals you throw at it, making plasma cutting the go-to choice for everything under the sun.

Cast iron

No cast iron is not an easy material to work with, but do not worry because plasma cutting will save the day for you. It effectively cuts through cast iron and gives you a flexible solution for various products. Making plasma cutting your go-to option can help you handle the formidable cast iron; it’s like having a reliable companion who’s always up for the task. 

Advantages of plasma cutting

Keep reading to know the benefits of this tech.

Clean cuts

Nobody desires more than to have a metal object with clean cuts and smooth edges. And you get this with plasma cutting tech. There is no need to perform the post-process finishing touches. You can just have a high-quality, perfectly finished product.


This is one of the primary advantages of plasma cutting tech. You can cut through very many electrically conductive materials effortlessly. Whether you have something made of steel, aluminum, copper, or stainless steel, it doesn’t matter at all. You will have a finely cut metal object. 

Speed & efficiency

If you think that it is going to take time to cut through a metal or alloy, you are wrong. This tech is capable of cutting through materials at a very high speed and that too efficiently. The high-temperature plasma arc makes this possible. So, as compared to old times methods, this method increases productivity and reduces labor hours. 

Precision & accuracy

You might be worried about whether it will give you a clean cut or not. Well, the truth is that you will surely have a precise cut at this high speed. Usually, there is an advanced technology, CNN tech, that helps you get precise and consistent cuts. 


Another advantage of plasma cutting tech is that this method is pretty cheap compared to other advanced techniques. The equipment involved in this process does not cost that much, and the electrodes & nozzles are also affordable. Because of this low price and affordability, smaller workshops & larger businesses are adopting plasma-cutting tech. 

Automation & CNN integration

You already know that CNN integration can enhance the entire process efficiently. Along with that, the automation can provide you with a perfect pattern of cutting the metal with ease. The overall program is formed in a way to reduce the need to have a post-cutting finishing process.

Environmental considerations

The best part of the entire process is that it is considered more eco-friendly than other methods. There is less discharge of waste materials, and the gasses used are less harmful. All in all, it is a win-win situation. 

Disadvantages of plasma cutting

Nothing comes without some loopholes. Here are the disadvantages:

Really thick material

A really thick material can be of concern because super-thick material is hard to cut. When you’re dealing with heavyweights, other cutting buddies like oxy-fuel cutting or laser cutting might be a better match.


Sometimes, what happens is that while slicing through a metal, there can be a bit of slant on the edges. This is called beveling. Some people might be okay with it, and some might not. Now, you might need some extra tools to reshape and give the finishing touches to the product. It’s like giving your metal pieces a little extra TLC to make sure they’re perfect for the job.

Initial cost

It would help if you were ready with every penny and dollar to start the process. Usually, the initial investment asks for high-tech equipment and setup for a proper process execution. However, some people might not have that much money. 

Gas usage

You are using gasses like nitrogen, oxygen, etc., for the process, and these gasses are not free. This means that you have to pay to get these gasses, and this can be an additional cost to the initial investment. So, it becomes a headache to keep an eye on the rising bills. 

Final words!

To summarize the article, let’s say that plasma-cutting tech is a game changer in the metal-cutting world. Yes, there are some drawbacks, and it works well with only conductive materials. The entire operation can be noisy as well. But it is the most versatile of the available advanced techniques. To get the best out of this plasma cutting, you must research well before starting the process. Although, we are sure this article must have cleared some of your doubts.

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