Comparison of Plasma, Oxyfuel and Lser

Plasma Advantages vs. Oxyfuel Better cut quality Greater material flexibility Significantly higher productivity Significantly lower cost per length of cut

Plasma Advantages vs. Laser Significantly higher productivity Increased flexibility to cut a wide range of material thicknesses and types Significantly lower capital, operating and maintenance costs

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Plasma provides the optimal mix of cut quality, productivity and operating cost

	Oxyfuel	Plasma	Laser
Cut quality	Good angularity Large heat-affected zone Dross levels require rework Not effective on stainless steel of aluminum	Excellent angularity Small heat-affected zone Virtually dross-free Good to excellent fine-feature cutting	Excellent angularity Small heat-affected zone Virtually dross-free Good to excellent fine-feature cutting with narrowest kerf
Productivity	Slow cutting speeds Pre-heat time increases pierce times	Very fast cutting speeds for all thicknesses Very fast pierce times Quick-disconnect torches maximize productivity	Very fast on thin material (less than 6mm - 1/4"); and slower on thicker material Long pierce times on thick material
Operating cost	Poor productivity and required rework drive cost per part higher than plasma	Long consumable life, good productivity and excellent cut quality drive the cost per part lower than other technologies	High cost per part due to power requirements, gas consumption, high maintenance costs and relatively low cut speeds on thick material
Maintenance	Simple maintenance requirements can often be performed by in-house maintenance groups	Moderate maintenance requirements: many components are serviceable by in-house maintenance groups	Complex maintenance tasks require specialized technicians

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Plasma Capabilities Chart

	Air Plasma	Oxygen Plasma	LongLife Oxygen Plasma	HyPerformance Plasma
System	Powermax1000 Powermax1250 Powermax1650	MAX200	HT2000 HT4400 HT4001	HPR130 HPR260
Cut Quality	Good Some secondary operations and dross	Better Some secondary operations with virtually no dross	Better Some secondary operations with virtually no dross	Best Minimal to no secondary operations with virtually no dross
Mild steel weldability	Nitriding can impair mild steel welding	Good mild steel welding	Good mild steel welding	Good mild steel welding
Productivity	Good	Better	Better	Best
Operating cost	Good	Good	Better	Best
Consumable life	Good	Good	Better	Best
Process flexibility	Good	Better	Better	Best
Features	Simple bundled system with minimal options	Lower degree of features and options	Lower degree of features and options	Fully featured with wide range of options
Application ranges	Light-duty cutting	Light- to medium-duty cutting	Light- to heavy-duty cutting	Precision cutting, light- to heavy-duty cutting
Price	Low	Medium	Higher	Higher

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Technology Benefits

	Oxygen Plasma	LongLife Oxygen Plasma	HyPerformance Plasma
Benefits of oxygen plasma vs. air plasma	Thicker capability 100% duty cycle Faster cut speeds Better cut quality, less dross Better weldability	Thicker capability 100% duty cycle Faster cut speeds Better cut quality, less dross Better weldability	Thicker capability 100% duty cycle Faster cut speeds Better cut quality, less dross Better weldability
Benefits of LongLife oxygen plasma vs. oxygen plasma		Significantly longer consumable life Significantly lower operating cost Faster cut speeds (HySpeed) Can be used on large machine frames	Significantly longer consumable life Significantly lower operating cost Faster cut speeds (HySpeed) Can be used on large machine frames
Benefits of HyPerformance Plasma vs. LongLife oxygen plasma			Significantly improved cut quality Better process resolution on low end for maximum cut quality on thin material Fuel-gas capability to improve stainless steel cut quality Mark and cut with same consumables Longest consumable life Highest cut speeds Auto gas console Quick-disconnect torch Bevel capability up to 45° Significantly improved marking quality

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Air Plasma: Powermax

Powermax Entry-level single gas (air or nitrogen) cutting systems, great for duct cutting, pipe cut-off, beveling and robotic 3-D cutting.

		Powermax1000	Powermax1250	Powermax1650
Capacity Mild steel	Dross free Production (pierce) Severance (edge starts)	n/a 10 mm (3/8") 32 mm (1-1/4")	n/a 10 mm (3/8") 38 mm (1-1/2")	n/a 12 mm (1/2") 44 mm (1-3/4")
Stainless steel	Production (pierce) Severance (edge starts)	10 mm (3/8") 32 mm (1-1/4")	10 mm (3/8") 38 mm (1-1/2")	12 mm (1/2") 44 mm (1-3/4")
Aluminum	Production (pierce) Severance (edge starts)	10 mm (3/8") 32 mm (1-1/4")	10 mm (3/8") 38 mm (1-1/2")	12 mm (1/2") 44 mm (1-3/4")
Speed* (Mild steel)	Optimum quality	10 mm (3/8") 1041 mm/m (41 ipm)	12 mm (1/2") 991 mm/m (39 ipm)	10 mm (3/8") 1447 mm/m (57 ipm)
Cut angle	ISO 9013 range**	5	5	5
Weldability		Preparation required	Preparation required	Preparation required
Process gases by material (Plasma/ shield)	Mild steel	Air	Air	Air
	Stainless steel	Air, N 2	Air, N 2	Air, N 2
	Aluminum	Air, N 2	Air, N 2	Air, N 2
Process amps	Not all processes available for all materials	20-60	25-80	30-100

* Note: Take care in comparison: competitors often show maximum cutting speeds rather than speeds that deliver the best cuts, as shown above. Cut speeds listed above deliver best cut quality, but cut speeds can be up to 50% faster.
** ISO 9013 is a standard that defines cut quality of thermally cut parts. The lower the range (range 1 is the lowest), the smaller the angle on the cut face. Cut angle in range 4 is better than in range 5.

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Oxygen Plasma: MAX200

MAX200 Entry-level oxygen cutting system, great for often-changing cutting requirements and production schedules. A proven production cutting system with an attractive initial capital cost.

		MAX200
Capacity Mild steel	Dross free Production (pierce) Severance (edge starts)	25 mm (1") 25 mm (1") 50 mm (2")
Stainless steel	Production (pierce) Severance (edge starts)	25 mm (1") 50 mm (2")
Aluminum	Production (pierce) Severance (edge starts)	25 mm (1") 50 mm (2")
Speed* (Mild steel)	Optimum quality	12 mm (1/2") 2159 mm/m (85 ipm)
Cut angle	ISO 9013 range**	4 - 5
Weldability		Ready to weld
Process gases by material (Plasma/ shield)	Mild steel	Air/Air, O 2/Air, N 2, CO 2
	Stainless steel	Air/Air, N 2/Air, N 2/CO 2, H35/N 2
	Aluminum	Air/Air, N 2/Air, N 2/CO 2, H35/N 2
Process amps	Not all processes available for all materials	40-200 beveling (200)

* Note: Take care in comparison: competitors often show maximum cutting speeds rather than speeds that deliver the best cuts, as shown above. Cut speeds listed above deliver best cut quality, but cut speeds can be up to 50% faster.
** ISO 9013 is a standard that defines cut quality of thermally cut parts. The lower the range (range 1 is the lowest), the smaller the angle on the cut face. Cut angle in range 4 is better than in range 5.

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