How long do plasma cutter consumables last?

Since we covered the role of each consumable in our blog "What are plasma cutter consumables" We wanted to discuss how long we can expect these elements to last.

The Nozzle and the Electrode will wear out more quickly than other components, as they are the consumables that are most directly involved with the creation and focusing of the cutting arc.

You will notice the Nozzle wear primarily in the quality of the cut that you are achieving.

As the Nozzle wears, the hole in the tip gets larger, which will make the plasma arc thicker and produces a wider cut (kerf) in your workpiece. You may also struggle to maintain a stable arc.

You will be able to do a simple visual inspection to sense when the hole in the nozzle becomes too large and requires replacing.

You will probably use 2-3 Cutting Tips to every 1 electrode. From our experience a Cutting Tip should last about 15 minutes of cut time on a std compressor and slightly longer with a dryer incorporated into the air system.

Dry air is essential, without it you will find yourself going through Cutting Tips very quickly!

From experience, cheaper/counter-fit style copies, IE eBay will burn out a lot quicker and can also cause some serious damage to your torch. A replacement torch is going to set you back around £450.

Replacing Electrodes & Nozzles

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As the electrode produces the arc, the hafnium insert melts and over time fragments are shot out through the torch in the cutting process, resulting in the development of a put in the end of the electrode.

This is perfectly normal, but when the pit grows deeper than around 1-1.6mm you will need to replace the electrode. This is because there will not be much hafnium left and you will soon start burning through the electrode itself.

This will make it extremely difficult to cut and could significantly damage the rest of your torch components.

It is difficult to be specific about exactly when you'll need to replace your nozzle & electrode, as this will depend on many factors, including the speed you cut, the thickness of the workpiece and the amount of amperage you are using.

It is a good idea however, to replace your nozzle & electrode at the same time for a fail safe method (according to whichever wears out first), as this will put you back to optimum cutting performance, rather than using a new electrode with a worn and inconsistent nozzle for example.

Your other components won't need replacing quite so often and are more likely to be dropped. Slag from the cutting process, the thermal dynamics and heating and cooling cycles.

Check your swirl ring and retaining cap regularly for any cracks and replace as soon as any appear.

It is good practice to change your swirl ring every fifth electrode replacement, if you are able to.

The shield cap will need to be cleaned of slag to ensure consistent airflow and should be replaced when the build up is too large to remove.

Replacing your consumables at the right time is essential for the maintenance of your machine and the accuracy of your cut.

Rest assured, here at Xtreme Plasma and our partnership with R-Tech Welding means that we can supply you with genuine plasma consumables of the highest quality for the P50CNC & P100CNC.

Tips to prolong the life of plasma cutter consumables

Cutting parameters: Cutting too quickly, too slowly or at the wrong distance from your workpiece will wear your parts more quickly.

Correct installation: Installing your components carefully and correctly is essential if they are to function properly. This includes making sure that the tolerances of the consumables match the amperage you will be using, as well as the correct assembly.

Monitoring: Keeping track of how your components are wearing will enable you to prevent a worn component from prematurely degrading another. You will need to change your nozzle and electrode more frequently than your other parts and leaving them too long will add strain to the whole system, as well as reduce your cut quality.

Please also check the O-Ring for cracks and wear. Periodically apply a small dab of the supplied torch grease, this will stop unnecessary air leaks that may cause an angled cut.