By Joe Gresh
Anyone who wants to become Vulcan must learn how to cut metal. There are many methods available like bandsaws, oxyacetylene torch, abrasive wheels, hacksaws and the old reliable, bend-it-back-and-forth-until-it-breaks. One of the relatively newer methods (in relation to the age of the Universe) is a machine called the plasma cutter.
Plasma cutters used to be very expensive. The plasma machine we use at school cost around 4000 dollars and is rated at 60 amps. The global economy (AKA China) has driven down the cost of plasma cutters dramatically. The Yeswelder cutter in this story cost me under 200 dollars and is rated 55 amps. Shipping was free.
In use, a plasma cutter works much like an oxyacetylene cutting torch. The big difference is that you don’t need any fuel: no acetylene gas to buy or bottles to rent. The only thing burning in a plasma cutting system is the material you are cutting through.
The plasma cutter uses regular compressed air and a bunch of ions and magical stuff inside the cutting head to create a super-hot, narrow stream of plasma. It’s sort of like having your own pocket-sized northern lights shooting out of the torch to cut material.
Unlike oxyacetylene, there is no waiting for the material to heat up. With a plasma cutter you set the torch near the material and pull the trigger. A jet of plasma shoots out of the torch and you can start cutting immediately. The plasma cutter cuts at about the same speed as an oxy cutter so you can move right along.
The 55 DS Pro Yeswelder plasma cutter will operate using 120 or 240 volts AC using the included adaptor. The machine auto selects for the voltage you are plugged into. At 120VAC input the machine will only go to 30 amps. You’ll need 240 VAC to access all 55 amps of metal slashing power
My air compressor is too small for the plasma cutter and is located too far away from where I cut so there’s a long air hose involved; with a long hose line pressure drops fast. I made a remote air tank out of a defunct water pump to give me a little more cut time and eliminate the line drop. I can cut 6 to 10 inches before I have to wait for the compressor to catch up. If you’re going to be doing a lot of continuous cutting with a plasma cutter you’ll need a decent sized air compressor.
With the compressor and the plasma cutter operating simultaneously, my smallish off-grid inverter struggles and spits out a low voltage alarm when the compressor starts. To get around this problem I use a fossil fuel powered 10KW Honda generator. The big V-twin Honda doesn’t even notice when I cut with the plasma torch and the air compressor kicks in.
Most everything you need to get started is included with the Yeswelder Cut-55. You’ll need to provide the air compressor and connect an air hose to the built in pressure regulator/filter on the back of the Yeswelder. Unless you cut through the torch hose or spill a Big Gulp container of Pepsi Cola inside the cutter, normal consumables are only the bits inside the torch that churn out ions.
The controls are pretty simple on the Yeswelder Cut-55. There is an amp setting, an air pressure setting, 2T or 4T trigger actuation (on-off with squeeze and release or squeeze on, release, torch stays on, second trigger pull turns off) an indicator for input voltage and not much else. It’s a simple machine to operate.
I haven’t used the machine very much; it cut through 1/8-inch steel like a hot jet of plasma through 1/8-inch steel. There’s not as much slag as with oxy cutting so clean up is easier. It should handle ¼-inch steel without a problem and I don’t work with anything thicker.
The prices on these Chinese plasma cutters are so much lower than the old line companies something must be sacrificed. I’m guessing in a full time metal shop the cheapo versions wouldn’t last long but for guys like me or you who just want to cut out a metal silhouette of a buffalo once in a while the Yeswelder looks like the goods. I give it a 5-star rating on the Hacksaw Chi-Com scale. That being said I have only one caveat: The thing may go up in a ball of exploding ions tomorrow. If it does quit I’ll be sure to report it in a follow up story.
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So that how they work… I have asked my mechanical friends how they work and all I get is shrugged shoulders . Thank you!
Thanks you for the lesson on the art of plasma cutting!
I wasn’t aware I had a chi-whatever scale . But thanks for the mention.
I’ve always wanted one mainly because of the cool name- “PLASMA CUTTER”. Who wouldn’t want one? The problem is my old Victor Star hacksaw is all I’ve ever needed. For bigger jobs I use my portaband or sawzall. What to do? Maybe someday, most likely never.
I think it will also work on aluminum???
Good info Joe. Ive always wondered about them and never been around one to see how they work.
Yes, anything electrically conductive.