Can you cut aluminum with a plasma cutter

Aluminum alloys continue to gain popularity in metal fabrication worldwide due in part to the ease with which these alloys can be fabricated—bent, welded, and most importantly, cut. The ease at which aluminum can be cut to shape and size can have a big influence on the cost and quality of subsequent operations and the final component itself. As with steel, the use of plasma arc cutting (PAC) on aluminum alloys is a popular choice for quickly producing high-quality cuts.

Cutting aluminum has some unique challenges compared to cutting steel or other common metals, particularly regarding the crack sensitivity and chemistry.  The techniques and best practices for cutting aluminum are very different than those for cutting steel.  In some cases, cutting aluminum needs to follow a particular procedure.  Important factors when cutting the material include a proper cutting technique and gas selection.

What Is The Best Gas For Plasma Cutting Aluminum?

A common problem seen plasma cutting aluminum is that you may not get a clean cut and have to spend a lot of time cleaning the edge down.

This is primarily due to the type of gas you are using.  Plasma cutters generally just need clean compressed air to clean cut other metals.  However, if you want a more precise clean cut when it comes to aluminum you will need to use an inert gas such as:

An argon/helium mix

or nitrogen

Cutting aluminum is really no different than cutting steel, with one exception: hydrogen gas builds when molten aluminum mixes with water.  Hydrogen can collect under the work plate on water tables, which creates a very hazardous condition.  Drop the water level to no less than 2″ below the bottom of the plate to let the hydrogen escape.  If you’ll be cutting large amounts of aluminum, we can install a table-length aeration/bubbler system, which uses compressed air to agitate the water and release the hydrogen.

Tips for Starting to Plasma Cut Aluminum

Base metal preparation is generally low effort when plasma arc cutting aluminum.  Unlike welding, the intense heat and velocity of the plasma column can push through thick aluminum oxide layers once the plasma column is developed.  Arc initiation—starting the cut—benefits from removing the oxide layer in the area where the work lead is connected to the workpiece and the area to be pierced.  In both places, use a stainless-steel wire brush to break up the aluminum oxide layer.  Starting cuts some distance from and with a smooth transition into the cut path is also beneficial to improving the cut quality.