60 amp consumables life

[BearNPum]

This is my info on observations of consumables life for the 60 amp torch on an LP-60I pilot arc torch.

I had posted some of this info on another thread, but will copy it here as well so that it is all together. First, I tested running the torch with the pilot only on for one minute, then I checked consumable wear on 100 pilot starts, then I ran a consumables set until I ran out of plate and time to do any more cutting.

Here are pics of a new tip and electrode:






First, I wanted to see what holding the pilot arc on without cutting does to the tip/electrode. I held the pilot arc on for 1 minute. Here are the pics:





So, keeping the pilot on does eat tips and electrodes, but not too bad considering this was a full minute. Other mfgs tips are rated to erode like 2.5 mm, and I don't know what these are speced or rated for, but this electrode and tip still look to have a lot of life left. As you will see later for my final cutting electrode, this electrode has plenty of life left.



Next, I used a new electrode with the same tip as before, and started the pilot arc 100 times.





I wished I had used another new tip, but it really looks like about the same additional erosion (or less) as the first test. The exit hole is looking a little uglier, but the bore is still very round as viewed from the backside. The electrode looks to have taken a bit more wear that the previous test, but in the same ballpark.

Last, I used a new tip and electrode, cutting until I gave up. I cut 3/16" plate, 6" wide, at about 35 amps. Initially, I was able to make 68 cuts, for a total of 34 feet of cutting. On about the last 5 cuts, the pilot didn't start regularly, and I had to pull the trigger a couple times to get things started, but once started, the cuts seemed as good as the first ones, but I believe I had to move just a little slower. When i tried to make cut 69, I couldn't get any pilot arc no matter how many times I pulled the trigger, and I couldn't get any arc touching the tip to the metal either. At this point I thought that was the end of the consumables, so I took the pictures below and figured that was the end of it.

Here are pics of those consumables after the 68 cuts:







The electorde is pretty eroded, but look at that tip, it looks like it could go many more miles. I did brush the soot off it, but it looks very nice. One thing I didn't do at this time was check the back of the tip, so not sure how bad it looked at this point.

On a later post here, jbman suggested that a loose electrode may have prevented the arc from starting. That sounded reasonable, so I reattached the consumables, and......... I did another 50 cuts!!! I stopped at 50 (for a total of 118 cuts or 59') because I was running out of time, scrap plate, and had a big mess on the floor. I could have made more cuts, but have no idea how many. I may someday reinstall these and cut again, but I am done for now. I tried to measure the electrode, which wasn't easy, and it looked to be eroded about 1.75 - 2 mm. Here are the final pictures, note the back of the tip is pretty nasty, but might be saved if it were possible to clean it with a small brush.

[Hamstn]

Thanks for the post. This goes along with the question I had in another post. I have since come across other posts that seem consistent with yours on the amount cutting one can do on a set of tips. Did you brush the tip off any time during your 68 cuts? Reason I ask I seen posted that it will extend the life of the consumables.

[jbman45]

Very nice posts and nice photos, thanks for taking the time as it really helps understand the debated issue of how long consumables last. I find brushing them does help quite a bit, but use a brass brush not a stainless one. Also, when the pilot arc won't start, pull off the cap and check the electrode as I find it will loosen a bit and/or loose a bit of electrical connection which I think does the start Then it's back to normal. Some places do sell separately the electrode from the cap piece so you can replace the part that fails if you want

[BearNPum]

I didn't brush the tip or electrode during use, only after cutting and before I took the pics.

I should have thought to tighten the consumables and see if they would keep going. I have seen that before when putting on a fresh set (loose electrode). I will try it soon and see if that last set will still cut.

[Uncle Ed]

I, too, wish to thank you for this report. For me, real world practical evidence is more compelling than specs on a box, etc. Even though those specs may have been based on exactly the type of trials that you used, it's great to have a confirmation.

Again, thanks for taking the time and effort to do this.

Ed

[KHK]

Excelent pictures!! EXCELENT POST!!

Thanks for sharing

[BearNPum]

On jbman's advice, I reattached the last consumables set (the one used for cutting the 3/16" plate), and, I cut another 50 cuts (25') of the 3/16" plate. I stopped because I was running out of time, scrap plate, and I had a pretty big mess on the floor. The consumables were still cutting, but as the pictures above indicate, they may be nearing the end of their life this time. I would like to know how far they would go, but I would have to go get some more plate, and I am actually tired of cutting straight lines. Later, when I have some scrap I may do some more cutting with those final consumables and actually take them to the end of their life.

I have updated the first post above with the new info and pics.

[Gadget]

I think the number of starts and stops also comes into play on the life of consumables. If you are making a lot of short cuts opposed to a few long cuts I think the life of the consumables is shortened some.
Another thing to consider, pierce cuts are harder on consumables than severance cuts.