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Assuming that you are cutting material within the dross free thickness capability

of the Fine Cut consumables .typically materials under 3/16 can be cut virtually dr
oss free .the best ways to minimize or eliminate dross are as follows:

Dross is usually caused by cutting too slow. Often, there is a fine line between
too slow and too fast ..and this is known as the dross free zone . If you are gettin
g excess dross ..do an experiment by increasing the cut speed by 5 or 10 inches pe
r minute on successive test cuts. Eventually you will find the dross free zone and
you typically want to be near the lower end of this dross free zone as that will
provide the best combination of edge squareness and minimal or easy to remove d
ross.
Dross can be caused by too much power (Amps) ..or too little power! I suggest sett
ing the power at the manufacturers suggested power level for the consumables you
are using and the material and thickness you are cutting .then do the speed exper
iment above.
Dross can be caused by torch standoff being too high .this will also cause a posit
ive bevel on the cut edge. Once again ..the consumables were designed in a laborat
ory full of engineers and technicians ..the published torch to work distances are
correct .so follow the manufacturers specs. If the book says .060 torch height .then
make sure that is where the torch operates and adjust the speed to improve the d
ross conditions.
Dross can be caused by improper air pressure and moisture, oil or other contaminan
ts in the air. As with torch standoff .air pressure is critical to ensuring the cu
t quality is at its best. By increasing air pressure over the torch manufacturer
s recommendations you are causing changes to the resistance and energy density o
f the plasma arc ..which will affect cut quality and nozzle and electrode life. If
the manufacturers specs suggest 70 psi then you should maintain that pressure for
best results.
Consumable condition ..if the orifice in the nozzle or the shield is not perfectly
round .or has nicks or blown-back material on the orifice bore .the cut quality in
terms of dross and edge angularity will definitely be affected. Long nozzle, shi
eld and electrode life is achieved by careful control of pierce height, pierce t
ime (get these recommendations from the torch manufacturers manual) as well as w
ith clean, dry air at the proper inlet pressure. Under the right conditions you
can literally get over a mile of cutting from one set of consumables!

I typically cut 3/16 material with no dross with my Powermax1000 with the FineCut
parts ..I expect dross on thicker materials. With my newer Powermax45 I am able t
o cut dross free to 3/8 and sometime ½ with similar cut quality to the Fine Cut part
s used on the 600, 1000, 1250 and 1650 systems.

Jim Colt

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