Hello all, I’m in need of some advice regarding cut quality.
A few months back I got a legacy Crossfire table with a chinese Forcecut 40D machine used. Pretty quickly I was able to run sheet metal parts (both aluminum and steel) without a ton of issue.
Recently I’ve developed a need to cut 1/8" and 1/4" aluminum and I’m struggling a TON. Cuts have severe beveled edges and I can’t get a clean cut edge to save my life. The Forcecut is a cheap box from china with no suggestions for current, air pressure, torch distance, cut speed, anything.
With 1/8 aluminum I’ve tried cut speeds from 60-100ipm, air pressures from 50-80psi, torch distances of .125" and 0.075" all at 40A current with no significant improvements between any changes. I’m running new consumables and a very small dessicant drier, emptying the air tank of any potential water before any cuts.
I want to know what level of cut quality I should expect from a machine like mine properly dialed in before I throw money at the problem for more test material, an air dryer, etc. Do I need a refrigerated dryer to make these clean?
Aluminum doesn’t cut clean. It will always have a rough edge. The dross doesn’t remove easily either. It’s less like the dross you get on steel and more like a torn edge that is still attached.
Some have found that coating the nozzle with anti-splatter gel might be helpful with all of the flecks of aluminum.
Check the consumables frequently because the flecks will foul the nozzle. Take the nozzle and swirl ring out to inspect all of the holes. You will likely need to replace your nozzle more frequently.
I know David cuts lots of aluminum. I have cut hundreds of pieces out of 10 gauge aluminum. Very messy stuff and very rough edge.
I am still working on my technique to remove the dross. Sanding, wire brush wheel or burnishing wheels seem more successful than the abrasive discs (in my experience).
We have been tumbling smaller aluminum parts using ceramic with good success , They get a dull appearance but if parts will be powder coated its fine. At this point we have a 5 gallon bucket tumbler (bucket in a bucket ) so we can tumble wet or dry, as well as a small cement mixer for larger parts, mainly de-drossing steel parts in the cement mixer. We have gotten some good results using nitrogen for aluminum for special jobs but more costly as compared to using the air compressor. Additionally a light mix of muratic acid will eat the crusty dross off. Just manage the process, dilution rate and soak time. K
trevzor4242
Those parts look pretty good pretty much what you will get with plasma.
I have a bunch of 3/4 aluminum 6061 plate. Test cuts were not so pretty , I think cutting aluminum @ 3/4 thick with a 65 amp plasma machine will require preheating and some additional finishing, machining but you can get a decent rough profile. Leave enough fat on it to clean up on the mill if its a critical part.
