Hardware: Plasma cutting

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Plasma cutting performed by an industrial robot
For fictional weapons, see plasma rifle and directed-energy weapon.
Plasma cutting is a process that is used to cut steel and other metals (or sometimes other materials) using a plasma torch. In this process, an inert gas (in some units, compressed air) is blown at high speed out of a nozzle; at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal away from the cut. Plasma can also be used for plasma arc welding and other applications.
Contents
1 Process
1.1 Starting methods
1.2 Inverter plasma cutters
2 Plasma gouging
3 CNC cutting methods
4 New technology
5 Costs
6 See also
7 External links
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Process

Freehand cut of heavy metal
The HF Contact type typically found in budget machines uses a high-frequency, high-voltage spark to ionise the air through the torch head and initiate an arc. The arc can only be formed if the torch is in contact with the job material. HF Contact type machines are not suitable for applications involving CNC cutting.
The Pilot Arc type uses a two cycle approach to producing plasma. First, a high-voltage, low current circuit is used to initialize a very small high-intensity spark within the torch body, thereby generating a small pocket of plasma gas. This is referred to as the pilot arc. The pilot arc has a return electrical path built into the torch head. The pilot arc will maintain itself until it is brought into proximity of the workpiece where it ignites the main plasma cutting arc. Plasma arcs are extremely hot and are in the range of 15,000 degrees Celsius.
Plasma is an effective means of cutting thin and thick materials alike. Hand-held torches can usually cut up to 2 in (48 mm) thick steel plate, and stronger computer-controlled torches can pierce and cut steel up to 12 inches (300 mm) thick. Formerly, plasma cutters could only work on conductive materials; however, new technologies allow the plasma ignition arc to be enclosed within the nozzle, thus allowing the cutter to be used for non-conductive workpieces.
Since plasma cutters produce a very hot and very localized "cone" to cut with, they are extremely useful for cutting sheet metal in curved or angled shapes.
Starting methods
Plasma cutters use a number of methods to start the pilot arc, depending on the environment the unit is to be used in and its age. Older cutters use a high voltage, high frequency circuit to start the arc. This method has a number of disadvantages, including risk of electrocution, difficulty of repair, sparkgap maintenance, and the large amount of radio frequency emissions. Plasma cutters working near sensitive electronics, such as CNC hardware or computers, use the contact start method. The nozzle and electrode are in contact. The nozzle is the cathode, and the electrode is the anode. When the plasma gas begins to flow, the nozzle is blown forward. A third, less common method is capacitive discharge into the primary circuit via a Silicon Controlled Rectifier.
Inverter plasma cutters
Analog plasma cutters, typically requiring more than 2 kilowatts, use a heavy mains-frequency transformer. Inverter plasma cutters rectify the mains voltage into DC, which is fed into either an IGBT or a MOSFET. With paralleled MOSFET transistors if one of the transistors activates prematurely it can lead to a cascading failure of one quarter of the inverter. Later invention, IGBT transistors when not used in this paralleled fashion will not blow out that easily. IGBTs can be generally found in high current machines where it is not possible to parallel sufficient MOSFET transistors. Switching frequency used ranges from about 10kHz to about 200kHz, depending on the ability of the switching transistors and rectifiers; higher switching frequency greatly reduces the magnetic flux in the step down transformer, and therefore the size of the transformer is reduced accordingly. The switch mode topology is referred to as a dual transistor off-line forward converter. Although lighter and more powerful, some inverter plasma cutters, especially those without power factor correction, cannot be run from a generator (that means manufacturer of the inverter unit forbids to do so; it is only valid for small, light portable generators). However newer models have internal circuitry that allow units without power factor correction to run on light power generators.
Plasma gouging
Plasma gouging is a related process, typically performed on the same equipment as plasma cutting. Instead of cutting the material, plasma gouging uses a different torch configuration (torch nozzles and gas diffusers are usually different),...(and so on)