Plasma Cutter Aluminum – Ultimate Guide

Plasma cutting can be used to cut aluminum, but it requires a machine specifically designed for this purpose. A plasma cutter is a tool that uses ionized gas and an electric arc to cut through various types of metals, including aluminum.

The process involves creating a high temperature plasma stream, which melts and cuts through the aluminum. However, not all plasma cutters are suitable for cutting aluminum, as the metal has a higher thermal conductivity and requires a machine with specific settings and adjustments.

Therefore, it is important to choose a plasma cutter that is designated for aluminum cutting and can provide clean, precise cuts. In this article, we will discuss the best practices for plasma cutting aluminum and recommend some of the top plasma cutters available in the market for this purpose.

Plasma Cutter Aluminum – Ultimate Guide


Understanding Aluminum

Aluminum is a popular choice when it comes to metal cutting projects. It’s lightweight, sturdy, and offers a great deal of versatility. However, before cutting aluminum using a plasma cutter, it’s important to have a clear understanding of its properties.

Here, we’ll explore the different alloys of aluminum, the thickness of aluminum that can be cut using a plasma cutter, and the unique properties that make aluminum an excellent choice for cutting projects.

Properties Of Aluminum That Make It Unique

Aluminum has some unique properties that make it an attractive choice for various cutting projects.

  • Lightweight: aluminum is a lightweight metal, making it easy to carry and handle.
  • High strength-to-weight ratio: although aluminum is lightweight, it has a high strength-to-weight ratio, making it strong and durable.
  • Corrosion-resistant: aluminum has excellent corrosion resistance properties, making it suitable for outdoor projects.
  • Heat-conductive: aluminum is a good conductor of heat, making it ideal for cutting applications that generate heat.
  • Non-magnetic: aluminum is non-magnetic, making it a suitable choice for cutting projects involving magnetic materials.

Different Alloys Of Aluminum

There are various alloys of aluminum available, each with different properties that make them suitable for different applications.

  • 1100: this is a soft and ductile alloy suitable for forming operations.
  • 2011: this alloy is perfect for machining operations, making it suitable for intricate cut designs.
  • 6061: this is a heat-treatable alloy that is strong and durable, making it an ideal choice for structural applications.
  • 7075: this alloy is strong and durable, making it suitable for aerospace and military applications.

Thickness Of Aluminum That Can Be Cut Using A Plasma Cutter

One of the most significant advantages of using a plasma cutter for aluminum cutting is its ability to cut through thick sheets of aluminum. Plasma cutters can efficiently cut through aluminum sheets of up to 1 inch thick, making them suitable for a wide range of cutting projects, from thin gauge aluminum to thick sheets of aluminum.

When cutting aluminum thickness, it’s important to adjust the settings of your plasma cutter correctly. A plasma cutter’s amperage, air pressure, and cutting speed must be adjusted according to the thickness of the aluminum you’re cutting. This ensures that your cuts are clean and accurate, making for a successful cutting project.

Understanding the properties of aluminum, different alloys, and thickness that can be cut using a plasma cutter is crucial for a successful cutting project. Whether you’re working on a diy project or a professional-grade cutting project, choosing aluminum and the right tools can make all the difference.

Using A Plasma Cutter To Cut Aluminum

Advantages Of Using A Plasma Cutter To Cut Aluminum

Plasma cutting has become increasingly popular in the metal fabrication industry as it offers significant advantages over traditional methods.

  • Fast and efficient: plasma cutters can cut through aluminum quickly and efficiently, saving time and increasing productivity.
  • High precision: plasma cutting produces clean, precise cuts, making it an ideal choice for intricate designs and details.
  • Versatile: plasma cutters can cut through a range of thicknesses, making them suitable for a variety of aluminum fabrication projects.
  • Clean cuts: unlike traditional cutting methods, plasma cutting doesn’t require any cleaning or finishing after the cutting process, making it a cost-effective option.

Best Practices When Using A Plasma Cutter On Aluminum

Using a plasma cutter on aluminum requires a certain level of skill and expertise.

  • Safety first: always wear protective gear, including goggles, gloves and a high-quality respirator to protect yourself from dangerous fumes and sparks.
  • Use the right settings: ensure that you are using the correct air pressure and amperage settings for the thickness of the aluminum you are cutting.
  • Keep the work area clean: remove any debris or contaminants from the work area before you begin cutting to avoid damaging the plasma cutter and producing inferior cuts.
  • Practice good technique: keep the plasma cutter at a consistent distance from the aluminum to produce even cuts and avoid damaging the material.

Importance Of Proper Positioning And Clamping When Cutting Aluminum

Proper positioning and clamping are essential when using a plasma cutter on aluminum.

  • Prevents warping: if the aluminum moves during the cutting process, it can cause warping or distortion, which can reduce the quality of the finished product.
  • Reduces the risk of injury: proper positioning and clamping help to keep the aluminum stable, reducing the likelihood of accidental injury or damage to the equipment.
  • Ensures accuracy: by positioning and clamping the aluminum correctly, you can achieve accurate cuts and maintain the integrity of the design.

Techniques For Cutting Aluminum With A Plasma Cutter

Cutting aluminum with a plasma cutter can be challenging, particularly when it comes to achieving clean, precise cuts.

  • Pierce the aluminum: before cutting, pierce the aluminum with the plasma cutter to create a starting point for the cut.
  • Use a guide: consider using a cutting guide to help you maintain a consistent distance between the plasma cutter and the aluminum.
  • Slow and steady: cut slowly and steadily to achieve more precise cuts and avoid overheating the plasma cutter.
  • Post-cut cleanup: after cutting, remove any slag or burrs that may have formed on the aluminum to achieve a clean finish.

By following these techniques and best practices, you can use a plasma cutter to cut aluminum with precision, efficiency and safety.

Ultimate Guide to Plasma Cutting

Common Issues And How To Address Them

Plasma cutters have been a game-changer for cutting different metals and materials. Aluminum cutting is one of the most common cutting tasks carried out by plasma cutters. However, cutting aluminum with a plasma cutter comes with its own set of challenges.

In this blog post, we will discuss some of the most common issues encountered when cutting aluminum with a plasma cutter and provide prevention tips and a troubleshooting guide for common problems encountered.

Common Issues Encountered When Cutting Aluminum With A Plasma Cutter

Cutting aluminum with a plasma cutter can be challenging due to its high reflectivity and thermal conductivity.

  • Excessive dross formation on the edges of the cut
  • Rough edges on the cut
  • Warping of the aluminum sheet during cutting

Prevention Tips

Here are some simple yet effective prevention tips that can help you avoid these common issues when cutting aluminum with a plasma cutter:

  • Use a plasma cutter with a higher power output to cut aluminum sheets
  • Avoid using a nitrogen plasma gas mixture when cutting aluminum, use argon or helium instead
  • Clean the aluminum sheet thoroughly before cutting it
  • Use a straight edge or cutting guide to keep the aluminum sheet flat and prevent warping
  • Use a good quality plasma cutter consumables such as electrodes and nozzles

Troubleshooting Guide For Common Problems

Despite taking all precautions, some common problems may still arise while cutting aluminum with a plasma cutter. Below are some guide points to troubleshoot the problem.

Dross Formation

Dross formation can ruin the edge of the cut and can make the surface really brittle.

  • Use a smaller cutting nozzle size.
  • Increase the gas flow of argon or helium.
  • Reduce the velocity and speed of the plasma cutter.

Rough Edges

Rough edges can cause issues with welding and the final finish of the material.

  • Increase the cutting speed.
  • Decrease the amperage of the plasma cutter.
  • Use the best quality consumables such as electrodes and nozzles.

Warping Of Aluminum

Warping of aluminum sheet can be another issue that can rise while performing the aluminum plasma cut

  • Use specialized cutting tools.
  • Keep working with top-quality cutting consumables.

To summarize, cutting aluminum with a plasma cutter can produce outstanding results, provided you are well prepared to handle its challenges. By following these prevention tips and troubleshooting guide guidelines, you can address the common issues encountered when cutting aluminum with a plasma cutter and obtain smooth, accurate, and efficient cuts.

Choosing The Right Plasma Cutter For Aluminum

How To Choose The Right Plasma Cutter For Cutting Aluminum

Aluminum is a soft metal, making it relatively easy to cut with a plasma cutter. However, not all plasma cutters are created equal, and not every plasma cutter is suitable for cutting aluminum.

  • Consider the thickness of the aluminum you will be cutting. Different plasma cutters can handle different thicknesses of metals, so make sure the plasma cutter you purchase can cut the thickness of the aluminum you will be working with.
  • Look for plasma cutters with high-quality torches. The torch should be lightweight and easy to handle, allowing you to make precise cuts smoothly. A high-quality torch should also have a long lifespan, making it an excellent investment in the long run.
  • Plasma cutters are available in both hand-held and mechanized models. While hand-held plasma cutters offer more portability and are better suited for small projects, mechanized models are more suitable for industrial use and large-scale projects.

Features To Look For When Buying A Plasma Cutter For Aluminum

When buying a plasma cutter specifically for cutting aluminum, there are certain features you should look for.

  • High-frequency start technology is crucial for a plasma cutter that can cut aluminum. This technology helps the plasma cutter to start easily without interfering with other electronic equipment.
  • The cutting speed is an essential factor to consider, as it determines how quickly you can complete your projects. Look for plasma cutters with fast cutting speeds, allowing you to work efficiently and meet your deadlines.
  • Choose plasma cutters that offer adjustable amperage, as this allows you to control the amount of heat and power needed to cut through different thicknesses of aluminum.

Budget Considerations

Plasma cutters for cutting aluminum can vary significantly in price, depending on their features and quality. Before making a purchase, consider your budget carefully. Keep in mind that a more expensive plasma cutter may have advanced features that allow for better precision and control, leading to improved project results.

However, more affordable models can still be effective and perform well for most diy projects.

Frequently Asked Questions Of Plasma Cutter Aluminum

Can A Plasma Cutter Cut Aluminum?

Yes, a plasma cutter can cut aluminum with high accuracy and precision.

What Type Of Plasma Cutter Should I Use For Cutting Aluminum?

You should use a plasma cutter with a dc output and higher amperage for cutting aluminum.

What Thickness Of Aluminum Can A Plasma Cutter Cut?

A plasma cutter can cut aluminum thickness ranging from 1/8 inch up to 1 inch or more, depending on the cutter’s power rating and amperage.

Is Aluminum Easier To Cut Than Other Metals With A Plasma Cutter?

No, aluminum can be challenging to cut due to its high thermal conductivity, which requires a higher concentration of heat to cut through.


We have seen that plasma cutting aluminum has become a popular method in metalworking. It offers numerous benefits, such as precision, speed, and versatility. Through plasma cutting, you can achieve cleaner and faster cuts with minimal distortion and heat-affected zones.

It is important to understand the factors that affect the quality of your cuts, such as plasma gas type and flow rate, amperage, and torch height. By optimizing these variables, you can achieve higher quality cuts and improve your productivity.

Additionally, proper maintenance and cleaning of your plasma cutter are crucial for its longevity and efficiency. We hope that this article has provided you with valuable insights into plasma cutting aluminum and its advantages in your metalworking applications. As always, keep exploring new techniques and technologies to improve the quality of your cuts and stay ahead of the competition.


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