Cutting Expanded Metal with a Plasma Cutter
Cutting expanded metal can be a challenging task if you're not equipped with the right tools and techniques. One of the most effective methods for achieving precise cuts in expanded metal is using a plasma cutter. This article will explore the benefits of using a plasma cutter for this purpose and provide some practical tips for getting the best results.
What is Expanded Metal?
Expanded metal is a versatile material that is commonly used in various applications, including fencing, walkways, and ventilation. It is made from sheets of metal that are sliced and stretched to create a mesh-like structure with an open area. This design provides strength while allowing light and air to pass through. However, the unique structure of expanded metal can make cutting it a bit tricky, especially when aiming for clean and accurate results.
Why Use a Plasma Cutter?
Plasma cutting has become a favored method for cutting various types of metal due to its efficiency and precision. The process involves using a high-velocity jet of ionized gas, or plasma, to melt and blow away material from the workpiece. For expanded metal, this technique offers several advantages
1. Speed Plasma cutters can operate at high speeds, making the cutting process quicker than traditional methods such as saws or shears. This is particularly advantageous when working on large projects or when multiple pieces need to be cut.
2. Precision Plasma cutting allows for highly accurate cuts, which is essential when dealing with expanded metal that requires tighter tolerances.
3. Minimal Distortion Unlike some cutting methods that generate significant heat and can cause warping, plasma cutting produces a narrower heat-affected zone. This means less thermal distortion, which is crucial for maintaining the dimensional integrity of the expanded metal.
Tips for Cutting Expanded Metal with a Plasma Cutter
1. Choose the Right Settings Before beginning, ensure that your plasma cutter is set to the appropriate amperage and voltage for the thickness of the metal being cut. This will help prevent issues such as rough cuts or excessive slag.
2. Secure the Workpiece Ensure that the expanded metal sheet is securely clamped down. This prevents movement during cutting, which can lead to inaccuracies and uneven edges.
3. Use the Correct Technique When cutting, maintain a consistent speed and distance from the material. Moving too quickly can result in incomplete cuts, while moving too slowly may cause excessive burn through or melting.
4. Wear Safety Gear Plasma cutting produces bright light and high temperatures, so it is essential to wear appropriate safety gear, including gloves, a welding jacket, and a proper helmet with suitable shade.
5. Clean the Edges After cutting, it may be necessary to clean up the edges to remove any slag or burrs that may have formed during the process. A flap disc grinder can be an effective tool for this purpose.
Conclusion
Cutting expanded metal with a plasma cutter can significantly enhance the efficiency and quality of your work. By utilizing this method, you can achieve cleaner cuts, reduce distortion, and improve overall productivity. With the right equipment, settings, and techniques, you can tackle your projects with confidence and precision. Whether you are a professional fabricator or a DIY enthusiast, mastering the art of plasma cutting expanded metal will undoubtedly elevate your metalworking skills.
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