Hello everyone. I was getting some pretty badly beveled cuts with the original consumables on my plasma cutter, which I chalked up to poor quality or damage by a beginner. So, after getting the new Z-axis and THC installed on my Crossfire XL, I swapped them out for some new 40A tips and electrodes from George. Unfortunately, the issue has persisted. It’s cutting like the torch isn’t mounted square (it is), and the angle of the cut follows the rotation of the nozzle (if I turn the tip 90 degrees, the direction of bevel changes accordingly). It’s behaving like the nozzle is blown out, but since the very first cut had the issue too, is there anything else within the nozzle assembly that could be causing this problem with brand new consumables?
My current setup is:
- Primeweld CUT60D
- 5HP 60 gallon air compressor in climate-controlled garage (16 CFM @ 90PSI, 165 PSI max) with after cooler, water separator, large desiccant dryer, air filter, and 1/2" ID line all the way to the plasma cutter.
- Cutting 1/4" mild steel with a 40A tip, 40A and 65 PSI set on the machine, 0.8s pierce delay and 38 IPM
- Steady voltage when cutting of 92-93V
- Stopping the program mid-cut to measure the height shows that it’s usually close to the 0.065" it’s supposed to be, though a few times I measured the gap at closer to 0.089"
- I verified the swirl ring is installed in the correct orientation, but even tried flipping it with no change
- The effect was present with the old tip and electrode, but was present immediately after switching to new consumables.
Torch is level with the table in both axis:
On a piece of 0.25" thick steel, it’s beveled 0.050" from top to bottom:
This is how much I have to tip the torch to cancel out the bevel:
Here’s the tip now, which doesn’t look noticeably damaged to my eye, and it only has 46 pierces and less than 5 minutes of cutting time on it:
And the electrode:
So, I guess I’m just trying to figure out if the tip is indeed already damaged after almost no use, and if so, is there something else in the setup that could be causing this to happen from the start? The tip has never had more than 40A to it, and since I’ve been testing, the torch hasn’t been on for more than 15 seconds continuously.
I would really appreciate any guidance, as I’ve ruled out everything that I can think of after many hours of reading forum posts! Thanks in advance!