Choosing the right cutting method can make or break your operation’s efficiency. Gas and plasma cutting are two of the most widely used processes; however, they differ in speed, precision, and the types of materials they can handle. If you’re trying to decide between gas cutting vs. plasma cutting, this guide can help. By the end, you’ll have a clearer picture of when to use which method and how to match the right system to your specific needs.
What is Gas Cutting?
Gas cutting, also known as oxy-fuel cutting, is a thermal cutting process that uses oxygen and fuel gas to cut through material. During this process, oxygen mixes with acetylene, propane, propylene, or natural gas. As a result, there’s an intensified chemical reaction within the steel oxidation process that allows for a powerful cutting force.
The flame preheats the steel to its ignition temperature, creating a chemical reaction between the oxygen and metal to form iron oxide — also referred to as “slag.” The oxygen jet removes the molten slag from the material, resulting in a clean cut.
What is Plasma Cutting?
Plasma cutting sends an electric arc through a gas that is passed through a constricted opening. The gas can be shop air, nitrogen, argon, oxygen, or another type of gas, depending on the operation. The machine elevates the temperature of the gas so much that it enters a fourth state of matter — plasma. This kind of cutting is great for any electrically conductive metal, including steel, aluminum, copper, brass, and other ferrous or non-ferrous metals.
Gas Cutting vs. Plasma Cutting: What’s Right for Your Business?
Whether you choose gas or plasma for your operation depends on a range of factors. First is the type of material. Oxy-fuel torches can only cut ferrous metals. For this reason, it can’t be used to cut aluminum or alloys like brass and bronze. Additionally, it is not a good match for cutting stainless steel. For cutting non-ferrous metals, plasma cutting is a more suitable option.
In addition to the type of material, the thickness also matters. Oxy-fuel is usually best for thicker materials, as plasma can have limitations for heavy-duty applications. Depending on the type of plasma cutting machine and consumables you use, you may be able to achieve up to 5 inches on stainless steel and 4 inches on mild steel. It’s best to talk with an experienced professional to determine what’s right for you.
The cut quality you need also determines which equipment you should use. Plasma cutting offers higher precision and accuracy compared to oxy-fuel cutting. Plasma also has a faster cutting speed, which can lead to higher productivity and efficiency.
The heat-affected zone (HAZ) will also be different for plasma and oxy-fuel cutting. Oxy-fuel generates significant heat, which can lead to a wider heat-affected zone. Conversely, plasma does not have as significant an impact. In fact, even dry plasma cutting has minimal impact on the HAZ.
These considerations should be taken into account before choosing a machine option. Talking to an expert can help you make an informed decision for your business.
Have More Questions on Gas Cutting vs. Plasma Cutting? Reach out to the AKS Team
If you need more clarification on gas cutting vs. plasma cutting, we’re happy to help. We’re well-versed in matching our customers with the right cutting system for their operation. We’ll work with you to understand your unique needs and recommend one of our durable, accurate, and reliable cutting systems.
Since 1912, AKS Cutting Systems and our parent company, Kiffer Industries, have been at the forefront of machine tool design and building from our factory headquarters in Cleveland, Ohio. As a fourth-generation, family-owned and operated company, AKS Cutting Systems is one of the only Made-in-the-USA manufacturers of CNC cutting machines for plasma, waterjet, and oxy-fuel solutions. Ready to see what we can do for your operation? Reach out to our team for a professional recommendation.