With a new set of consumables correct parameters and good steel:
Normal plasma (Cutmaster / Powermax etc) 0 -10 degrees
High Definition plasma (HPR / Ultracut / Proline) 0-3 degrees
This obviously is more apparent the thicker the material being cut.
Hole Sizes (Minimum diameter)
Normal plasma 1.5 x plate thickness
High Definition 1 x plate thickness
Realistic minimum hole diameter is around 5mm due to physical size of plasma arc.
Normal plasma will leave more dross than high definition.
Dross will normally occur where the machine has to slow down i.e. corners and small holes.
Low speed dross
See above – flakes of material, easily removed with a scraper (comes off in large pieces)
High speed dross
Not as common as Low speed dross – small beads of material along cut edge hard to remove.
The outside of the shape should be cut clockwise.
Holes should be cut anti clockwise.
On flexi shapes this is automatic.
On ‘in office’ software this is normally an option.
These should always be fitted as matched set (especially on High definition plasma where there are many combinations)
Always ensure parts are kept clean during fitting.
On a Powermax / Cutmaster generally only the nozzle changes for the different currents.
On a high definition usually everything is different.
As a rule of thumb you would expect to change 3 to 4 nozzles for each electrode.
Gas flow / Pressures
Gas pressures /flows should be set with gas flowing through the torch – if a static pressure is set it will lead to reduced pressure during cut leading to poor cut quality.
Supply pressure to machine
Ensure all gas supplies to the plasma are set to manufacturers recommended values and they do not drop during cutting (particularly important if compressor is shared between several pieces of equipment) if pressure drops it will give spurious errors on the plasma / poor cut quality.