A Guide to All Gases You Can Use
Plasma cutting is a highly efficient and versatile cutting process that involves using a high-velocity jet of ionized gas to melt and cut through metal. One of the key factors that determine the quality and efficiency of the plasma cutting process is the type of gas used. Different gases have different properties that affect the cutting speed, precision, and quality of the cut. Therefore, choosing the right gas for your plasma cutting application is crucial for achieving optimal results.
There are several gases that can be used for plasma cutting, including compressed air, oxygen, nitrogen, argon, and hydrogen. Compressed air is a popular and affordable option for plasma cutting, as it is readily available and does not require any special equipment or handling. Compressed air can provide a clean and precise cut on thin to medium thickness metals, making it a good choice for hobbyists, DIYers, and small-scale operations.
However, for more demanding applications that involve cutting thicker or harder metals, other gases such as oxygen, nitrogen, or argon may be more suitable. Each gas has its own unique properties that affect the cutting process, such as the level of oxidation, thermal conductivity, and ionization potential. Therefore, it is important to understand the characteristics of each gas and choose the one that best matches your cutting needs.
What is Plasma Cutting Gas?
Plasma cutting is a process that uses a high-temperature, high-velocity stream of ionized gas, or plasma, to cut through metal. The plasma is created by ionizing a gas, which is then directed through a nozzle to the workpiece. The gas used in plasma cutting is an important factor in the cutting process, as it affects the quality of the cut and the speed at which it can be made.
Common gases used for plasma cutting are compressed air, nitrogen, argon, hydrogen, and oxygen, or blends of two or three of these components. Each gas has its own advantages and disadvantages, depending on the type of metal being cut and the thickness of the material. Here is a breakdown of the different gases used for plasma cutting:
Gas | Metal Type | Advantages | Disadvantages |
Compressed Air | Mild Steel | Low cost, good quality cut | Not suitable for non-ferrous metals |
Nitrogen | Stainless Steel, Aluminum | High-quality cut, good for thin materials | Higher cost than compressed air |
Argon | Stainless Steel, Aluminum | High-quality cut, good for thin materials | Higher cost than compressed air |
Hydrogen | Stainless Steel, Aluminum | High-quality cut, good for thick materials | Explosive, requires special handling |
Oxygen | Mild Steel | High-speed cut, good for thick materials | Not suitable for non-ferrous metals, higher cost than compressed air |
The cost of the gases used in plasma cutting varies depending on the type of gas and the supplier. Compressed air is the least expensive option, while hydrogen is the most expensive due to its explosive nature and special handling requirements. Here is a breakdown of the gases used for plasma cutting by price:
- Compressed Air – Lowest cost
- Nitrogen – Mid-range cost
- Argon – Mid-range cost
- Oxygen – Mid-range to high cost
- Hydrogen – Highest cost
Types of Plasma Cutting Gas
Argon
Argon is a commonly used gas for plasma cutting, especially for non-ferrous metals like aluminum and copper. It provides a stable arc and produces a clean cut, making it ideal for precision cutting. However, it is more expensive than other gases and may not be the best choice for thicker materials.
Hydrogen
Hydrogen is a highly reactive gas that is used for cutting stainless steel and other high-alloy materials. It produces a very hot flame that can cut through thick materials quickly, but it can also be dangerous to work with due to its flammability. Hydrogen is also more expensive than other gases.
Nitrogen
Nitrogen is a versatile gas that can be used for cutting both ferrous and non-ferrous metals. It produces a clean cut and is less expensive than argon or hydrogen. However, it may not be the best choice for thicker materials or for materials that require a high-quality finish.
Oxygen
Oxygen is the most commonly used gas for plasma cutting. It is inexpensive and can be used for cutting a wide range of materials, including mild steel, stainless steel, and aluminum. Oxygen produces a very hot flame that can quickly cut through thick materials, but it can also produce a rougher cut and may require additional finishing work.
When it comes to cost, compressed air is the cheapest option, followed by nitrogen and oxygen. Argon and hydrogen are the most expensive gases to use for plasma cutting.
Here is a table summarizing the different gases and their uses:
Gas | Materials | Advantages | Disadvantages |
Argon | Non-ferrous metals | Stable arc, clean cut | Expensive, may not be suitable for thicker materials |
Hydrogen | Stainless steel, high-alloy materials | Hot flame, quick cutting | Expensive, dangerous to work with |
Nitrogen | Ferrous and non-ferrous metals | Versatile, clean cut | May not be suitable for thicker materials or high-quality finishes |
Oxygen | Mild steel, stainless steel, aluminum | Inexpensive, hot flame, quick cutting | Rougher cut, may require additional finishing work |
Using a Normal Home Workshop Air Compressor for Plasma Cutting
One of the most common questions asked by hobbyists and DIY enthusiasts is whether a normal home workshop air compressor can be used for plasma cutting. The answer is yes, but with some limitations.
The air compressor must have a minimum of 60 gallons of air capacity and a minimum of 5 horsepower. This is because plasma cutting requires a high volume of air to create the plasma arc. A smaller compressor may not be able to provide enough air pressure to support the plasma cutting process.
Additionally, the air compressor must have a moisture trap and air filter to remove any moisture or impurities from the compressed air. Moisture and impurities can negatively affect the plasma cutting process and damage the plasma cutter.
It is important to note that using a normal home workshop air compressor for plasma cutting may not provide the same level of performance as a plasma cutter with a built-in air compressor. However, it can be a more affordable option for those who already have an air compressor and are looking to add plasma cutting to their workshop.
Types of Gases for Metal Cutting
There are several types of gases that can be used for metal cutting, each with their own benefits and drawbacks. Here are some of the most common gases used for metal cutting:
Gas | Benefits | Drawbacks | Price |
Air | Readily available, affordable | Not suitable for thick metals | Low |
Oxygen | Highly efficient for thick metals | Can cause oxidation and warping | Medium |
Nitrogen | Produces clean cuts, minimal oxidation | Not suitable for thick metals | High |
Argon | Produces clean cuts, minimal oxidation | Not suitable for thick metals | High |
It is important to choose the right gas for the type of metal being cut and the thickness of the metal. Using the wrong gas can result in poor quality cuts and damage to the metal.
Factors to Consider When Choosing Plasma Cutting Gas
When it comes to plasma cutting, selecting the right gas is crucial to ensure the quality of the cut and the efficiency of the process. Here are some key factors to consider when choosing plasma cutting gas:
Material Being Cut
The type of material being cut is a significant factor in determining the right plasma cutting gas. Different gases are suited for different materials. For instance, nitrogen is often used for cutting aluminum, while oxygen is suitable for cutting mild steel.
Cutting Speed
The cutting speed is another important factor to consider when selecting plasma cutting gas. Some gases are more effective at high cutting speeds, while others are better suited for slower speeds.
Cut Quality
The quality of the cut is also a crucial consideration when choosing plasma cutting gas. Some gases produce cleaner cuts than others, while some may leave behind slag or dross.
Cost
The cost of the gas is also a significant factor. Some gases are more expensive than others, and the cost can vary depending on the supplier and the region.
Here are some of the gases commonly used for plasma cutting:
Gas | Material | Price |
Oxygen | Mild Steel | $$ |
Nitrogen | Aluminum | $$$ |
Argon | Stainless Steel | $$$$ |
Hydrogen | Non-Ferrous Metals | $$$$$ |
It’s important to consider all of these factors when selecting the right plasma cutting gas for your project. By choosing the right gas, you can ensure a high-quality cut and an efficient process.
Advantages of Plasma Cutting Gas
Plasma cutting gas is a highly efficient and precise method for cutting metal. Here are some of the advantages of using plasma cutting gas:
- High cutting speed: Plasma cutting gas can cut through thick sheets of metal at a much faster rate than other cutting methods like oxy-fuel cutting. This is because plasma cutting gas uses a highly focused jet of ionized gas to melt and blow away the metal.
- High precision: Plasma cutting gas can produce highly precise cuts with minimal kerf width. This makes it ideal for cutting intricate shapes and designs in metal.
- Wide range of materials: Plasma cutting gas can be used to cut a wide range of metals, including steel, stainless steel, aluminum, and copper. It can also be used to cut non-metallic materials like plastics and composites.
- Minimal heat affected zone: Plasma cutting gas produces minimal heat affected zone (HAZ) compared to other cutting methods. This means that the metal around the cut remains relatively cool, reducing the risk of warping and distortion.
- Low noise and fume levels: Plasma cutting gas produces less noise and fumes compared to other cutting methods, making it a safer and more environmentally friendly option.
When it comes to plasma cutting gas, there are several different types of gases that can be used. Here are some of the most common gases used for cutting different types of metals:
Metal Type | Gas Type | Price |
Steel | Oxygen | Low |
Stainless Steel | Nitrogen/Hydrogen | Medium |
Aluminum | Argon/Helium | High |
Overall, plasma cutting gas is a highly efficient and precise cutting method that offers several advantages over other cutting methods. By choosing the right gas for the metal being cut, users can achieve optimal results while also keeping costs under control.
Disadvantages of Plasma Cutting Gas
While plasma cutting gas has many advantages, it also has some disadvantages that should be considered before choosing this cutting method. Here are some of the main disadvantages of plasma cutting gas:
- Noisy: Plasma cutting can be very noisy, which can be a problem in some environments. It is important to wear ear protection when working with plasma cutting gas.
- Not suitable for thick materials: Plasma cutting is not as effective for cutting thick materials as other cutting methods such as oxy-fuel cutting or waterjet cutting.
- Requires frequent gas replacement: Plasma cutting gas needs to be replaced frequently, which can be expensive and time-consuming.
- Produces hazardous fumes: Plasma cutting can produce hazardous fumes that need to be properly ventilated to ensure worker safety.
When it comes to choosing the right gas for metal cutting, there are several options available. Here are some of the most common gases used for different metal cutting types:
Gases | Metal Cutting Type |
Oxygen (O2) | Oxy-fuel cutting |
Nitrogen (N2) | Laser cutting, plasma cutting, waterjet cutting |
Hydrogen (H2) | Oxy-fuel cutting, plasma cutting |
Argon (Ar) | Laser cutting, plasma cutting |
The price of these gases can vary depending on the supplier and location. Oxygen is generally the least expensive gas, while argon is the most expensive. Hydrogen is also relatively expensive due to its high production and transportation costs.
Cheap Plasma Cutter Overview
Here’s a breakdown of the different plasma cutting gases by price:
Gas Type | Price Range |
Air | $200 – $2,000 |
Nitrogen | $2,000 – $10,000 |
Oxygen | $3,000 – $15,000 |
Keep in mind that the price of a plasma cutter can also depend on other factors, such as the brand, cutting capacity, and additional features. It’s important to do your research and compare different models to find the best cheap plasma cutter for your needs.
Conclusion
Plasma cutting is a highly efficient and precise method of cutting through metal materials. The use of ionized gases at high temperatures allows for a clean and accurate cut, making it a popular choice for metal fabricators and manufacturers. However, the choice of gas used in the plasma cutting process can have a significant impact on the quality of the cut and the overall cost of the operation.
There are several types of gases commonly used in plasma cutting, including compressed air, nitrogen, oxygen, argon-hydrogen, and argon. Compressed air is the most commonly used gas due to its low cost and availability, but it is only suitable for cutting thin metals. Nitrogen is a popular choice for cutting stainless steel and aluminum, while oxygen is used for cutting carbon steel. Argon-hydrogen is used for high-precision cutting of non-ferrous metals, while argon is used for cutting thicker materials.
The cost of the gas used in plasma cutting can also vary depending on the type of gas used. Compressed air is the most affordable option, while nitrogen and oxygen are more expensive. Argon-hydrogen and argon are the most expensive gases, but they offer superior cutting quality for certain types of metals.
When choosing a gas for plasma cutting, it is important to consider the type of metal being cut, the thickness of the material, and the desired cutting quality. By selecting the appropriate gas for the job, manufacturers can ensure a high-quality cut while also minimizing the overall cost of the operation.
