Plasma cutting is one of the most effective techniques used in steel fabrication, largely thanks to its precision and efficiency which are key for delivering projects on time.
At Carver Engineering, we specialise in providing world-class steel fabrication services for a number of sectors throughout the UK, such as rail, highways and construction.
In this article, we’ll discuss the ins and outs of plasma cutting, how it works, and the kinds of projects we can complete using this technique. We’ll also explore pros and cons of this cutting method in comparison with other techniques and how you can leverage plasma cutting in your next project with Carver Engineering.
What is plasma?
It’s an important part of the process, but what actually is plasma? While solids, liquids and gases are the most commonly heard of states of matter, there is actually a fourth one – and that’s plasma.
When gas is heated to extremely high temperatures, this causes its atoms to collide with enough energy to free electrons, creating a mixture of charged particles. And thus, plasma is formed.
This plasma is then used in a variety of industrial applications, such as steel fabrication, thanks to its ability to conduct electricity and generate intense heat. When it comes to plasma cutting, As well as steel fabrication, this electrically conductive gas (or plasma) is used in a variety of industrial applications because it can conduct electricity and generate intense heat.
What is plasma cutting?
Plasma cutting is a process that uses a high-velocity jet of plasma to cut through conductive materials such as steel. The plasma is created by heating a gas (like compressed air, oxygen, or nitrogen) to the point where it becomes electrically charged and highly energised. Then, once it’s up to temperature, it easily, quickly and precisely slices through metal sheets.
The plasma cutting process in a nutshell
Here’s how a plasma cutter works…
- The plasma cutter uses an electric arc to ionise the gas, turning it into plasma.
- A stream of plasma hot enough to melt metal is then expelled through a focused nozzle at incredibly high speeds.
- The plasma jet melts the metal upon contact, and the high-velocity gas blows away any molten metal to leave a clean and precise cut.
Plasma cutting is known for its ability to cut through medium-thick and thin metals with high accuracy, making it a preferred method in steel fabrication for tasks ranging from cutting large steel sheets to producing intricate components.
At Carver Engineering, we utilise advanced equipment to ensure that our cuts are accurate, smooth, and ready for further processing or fabrication.
What is plasma cutting used for in steel fabrication?
Here are some examples of the key applications we use plasma cutting for as part of our steel fabrication services:
1. Structural steel components
Plasma cutting is commonly used to fabricate the core components of structural steel frameworks. This includes cutting steel beams, plates, and columns which are then used in the construction of bridges, buildings, and other large infrastructure.
From intricate cuts to high throughput, using plasma cutting for structural steel ensures that all components for the construction project are delivered on time and to exact specifications.
2. Steel plate processing
Many industrial projects, like steel bridges, are made up of large steel plates. Whether they need to be cut into specific shapes or have holes and slots added, plasma cutting allows for the precise shaping and profiling of these plates. This makes plasma cutting one of the go-to methods for processing these heavy-duty materials.
3. Steel erection and assembly components
In construction, steel structures must be assembled with precision. Plasma cutting is used to create components such as connection plates, brackets, and fittings, which are critical for steel erection and assembly. An accurate cut ensures these parts fit together perfectly on-site, reducing the risk of errors and delays during installation.
4. Machinery and equipment fabrication
Plasma cutting is also used to shape machinery parts like gears, housings, and other metal components that need to withstand high levels of stress in industrial environments, such as mining.
5. Repair and retrofitting
Plasma cutting can also be a great option for repairing and refurbishing steel parts. For example, this could involve cutting out worn or damaged sections of steel structures and replacing them with newly fabricated parts. With plasma cutting, these old materials can be removed and replaced quickly, minimising downtime should repairs need to be made.
Advantages and disadvantages of plasma cutting
While plasma cutting is the perfect technique for certain projects, as with any industrial process, it comes with its own set of benefits and drawbacks. Our team of highly experienced engineers are best placed to advise you on the best approach for your specific project.
Advantages:
- Speed: Plasma cutting is extremely fast compared to other methods, especially when cutting thin materials, taking around ¼ of the time of most similar cutting techniques. This allows for quicker turnaround times in fabrication projects.
- Safety: Unlike oxy-fuel, plasma cutting relies on inert gases, making it a safer option as it isn’t prone to explosion or ignition.
- Versatility: Plasma cutters can handle a wide range of materials. Plasma cutters can also handle curves and unique shapes.
Disadvantages:
- Thicker materials: While plasma cutters provide precise cuts for thin and medium-thickness steel sheets, they aren’t as effective for cutting through denser materials.
- Heat-Affected Zone (HAZ): Plasma cutters generates high temperatures which can create a ‘heat-affected zone’ along the edges of the cut, which may require additional post-processing.
What other cutting techniques are used in steel fabrication?
Depending on the project, there are other techniques commonly used in material processing, including…
Laser cutting: A focused laser beam is used to melt and cut through metal, leaving a precise, smooth-edge finish. It can be slower and more expensive than plasma cutting.
Oxy-fuel cutting: This method uses a combination of oxygen and fuel gases to create a flame hot enough to melt steel. While it works great for thicker materials, it isn’t as precise as plasma cutting.
Water jet cutting: A high-pressure stream of water mixed with an abrasive material is used to cut through metal. This method is precise and doesn’t create a heat-affected zone, however, it is generally slower and more expensive.
Mechanical cutting: This includes traditional methods like shearing or sawing , which are effective for straight cuts but are less flexible when it comes to intricate or curved designs.
Take your steel fabrication project from concept to completion with Carver Engineering
When it comes to steel fabrication, Carver Engineering is equipped to handle every stage of your project, from detailed design to delivering components ready for installation. With state-of-the-art plasma cutting technology and a highly skilled team, we ensure precision, efficiency, and reliability in all of our work.
Whether you’re working on a steel bridge, beams and frames, pipeline fabrication or something else entirely, we have the expertise to deliver high-quality results. Check out some of our recent projects here and see for yourself the high standard of craftsmanship we bring to every job.
Ready to get started on your steel fabrication project? Contact us today to discuss your project requirements and learn more about how we can take your concept from design through to completion.
