Going through plasma tips

**ghank** · 03-19-2010, 10:32 AM

I recently got a a 520D and I do love it for tig and plasma cutting. Only problem I am having is going through the long plasma tips. I am cutting sheet metal and 1/8" mild steel. The hole in the tips seem to enlarge and then the end of the hole drifts in one direction so the stream is not straight anymore. I am also building up a lot of slag on the tip. I can cut 2-4 feet before I need to clean the slag off, or replace the tip. Is that normal or am I doing something wrong? I am using 110v, 65-80lbs air.

**Gadget** · 03-19-2010, 04:29 PM

Welcome to the forum Ghank. Are you dragging the tip or otherwise making contact with the metal? For best results you should maintain 1/16 to 1/8th inch distance from the metal. Also, are you pierce cutting? That will also reduce tip life if you pierce with the tip too close.
When you get a chance please post some information about yourself in the Introduce Yourself section so we can get to know you.
Dan

**ghank** · 03-20-2010, 09:38 AM

On the thinner sheet metal I am dragging the tip. For 1/8", I keep the tip off of it 1/8". I do pierce cut sometimes. On the long cuts I stop and start to reposition myself. I appreciate the help!

**KHK** · 03-20-2010, 10:37 AM

Take a look at the following links.
Plasma cutting table
Plasma cut on .070 SS
Plasma cut on 1/4 in AL
The interesting thing is the air pressure and amperage used to make these cuts.
High air pressure, amps, drag cutting will eat up consumables,
Adjust the machine and air pressure to the work.

**ghank** · 03-20-2010, 10:45 AM

Thanks! I'll give it a shot.

**jbman45** · 03-20-2010, 11:00 AM

Your tip says a lot about what you are doing right and wrong. you mentioned the hole in the tip gets slanted away from perfectly round....that means you are not holding your torch straight, but at an angle which increases wear and in the side direction. If you think you're a 1/16 of an inch off the metal but you are at an angle then you really are much farther. so try to stay perpendicular to the metal or better use a guide for awhile to see how it cuts.

If your hole enlarges too quickly you are probably too far from the workpiece or you're playing with it and starting the arc with no metal, i.e. in thin air to see it work. either will round out the hole.

sounds like everything is working, just have to get a little more time on it..

**BearNPum** · 03-22-2010, 11:26 AM

Not sure what the answer is for your particular torch and setup, but tips and electrodes should go a long time. Here - 60 amp consumables life is info on my life testing of the 60 amp tips on my unit. I cut 59' of 3/16 and the tip/electrode was still going, although with some degradation of the cut.

**Icutone2** · 08-11-2010, 02:22 PM

Thanks Keith for posting the plasma table pic. oops no pic. ghank welcome to the forum.
Lee

**Firefightaz** · 11-24-2010, 06:51 AM

The excessive slag buildup is a problem sometimes. I have found that a 100grit sandpaper sponge works great to brush off and clean the slag from your tip. It's not rough enough to damage or degrade and it does a great job at knocking that crap off.