How to maximize plasma gouging outcomes with Powermax SYNC

In this video, we will explain how to get the best gouging results when you are using the Hypertherm gouging cartridge on Powermax SYNC™ systems and gouging by hand.

What is plasma gouging?

Plasma gouging is used to remove metal from a workpiece without piercing or severing it. A plasma arc between the torch and the workpiece melts the surface metal, and a gas jet blows the molten metal away from the workpiece. Gouging is frequently used to remove unwanted metal in preparation for welding and casting. With practice, you can achieve smooth, clean, and consistent gouges with plasma.

Plasma gouging has many advantages:

• Plasma works on any conductive ferrous or non-ferrous metal, including mild steel, stainless steel, aluminum, and copper.

• You can work at faster operating speeds and spend less time on primary or secondary grinding work when you use plasma gouging.

• Plasma gouging makes less noise and creates less debris in the work environment than carbon-arc gouging, helping you meet regulatory and workplace safety requirements.

• There are no carbon contaminates or workpiece contamination with plasma gouging.

• Plasma gouging is safer than oxyfuel and carbon-arc gouging.

• Plasma gouging requires less operator training time and has a shorter learning curve than alternatives.

• Plasma cutterscan perform efficient spot weld removal using the gouging technique on automotive body panels made of high strength steel.

Plasma gouging with Powermax SYNC

The Powermax SYNC series has built-in intelligence and a revolutionary single-piece cartridge consumable to help streamline system operation, lower operating costs, and maximize gouging performance. The easy-to-identify single-piece cartridge consumables are color-coded by process and laser marked with part numbers to eliminate parts confusion and simplify consumable inventory management.

SmartSYNC® torch application-specific cartridges automatically set the correct amperage and operating mode based on the cartridge you install. Each gouging cartridge has been designed to optimize the gouging process for the best performance possible, and the advanced cartridge consumable design provides up to twice the cutting time of traditional consumables when hand gouging. This simple system minimizes downtime, troubleshooting, and training time.

Gouging cartridges: getting started

To begin, make sure the system is turned on with the torch in the lock, or yellow, position. Also make sure the work cable and input gas supply are properly connected and the ground clamp is attached to the workpiece or table ground.

Next, install the appropriate gouging cartridge for your current application onto the SmartSYNC™ torch base. The cartridge will automatically select the gouging process and amperage on the power supply. All gouging cartridges for the SmartSYNC torch are green, but there are different part numbers to choose from depending on the amperage and type of gouge you want to produce.

Maximum Control cartridges

Maximum Control cartridges are designed for more precise metal removal, light material washing, and for when a shallow gouge is desired. Slower gouging speeds are recommended with Maximum Control cartridges. The diffuse plasma arc provides better visibility than Maximum Removal cartridges. If you are just learning to gouge, you may want to start with Maximum Control cartridges to prevent any workpiece damage.

Maximum Removal cartridges

Maximum Removal cartridges are designed for aggressive metal removal applications, deep gouge profiles, and extreme metal washing. Faster gouging speeds are recommended to control the concentrated plasma arc.

The decal on top of the Powermax SYNC shows the image, amperage, and part number for each cartridge. There is an icon next to each cartridge that represents the application.

Begin plasma gouging

With the desired gouging cartridge installed, move the torch-lock switch into the green position. Before you begin using any Powermax SYNC system, always wear appropriate personal protective equipment, including gloves, eye protection, and protective clothing. Once you put on your personal protective equipment, you are ready to gouge.

To initiate a gouge, hold the torch at a 40-degree angle with the cartridge between ¼ to ½ inch, or 6 to 12 mm, from the workpiece. When you press the trigger, a pilot arc will start. Transfer the arc to the workpiece by moving the pilot arc closer to the metal. Once the arc has transferred, pull the torch back from the material and stretch the arc to about 1¼ inches, or 32 mm.

Push the plasma arc in the direction of the gouge you want to create. Keep a small distance between the cartridge and the molten metal to avoid damaging the cartridge or torch. Sustaining the maximum arc stretch while gouging will produce the optimal gouge profile.

Changing the gouge profile

The gouge profile is the shape left after removing metal from a workpiece. There are several ways to change the gouge profile to fit your needs.

• You can vary the gouge profile by changing the speed of the torch movement. Increase the speed of the torch movement to make the gouge narrower and shallower. Decrease the speed of the torch movement to make the gouge wider and deeper.

• You can change the angle of the torch to the workpiece to change the width and depth of the gouge profile. Put the torch in a more upright position to make the gouge narrower and deeper. Tilt down the torch so that it is closer to the workpiece to make the gouge wider and shallower.

• You can vary the torch-to-work standoff distance to produce a different gouging profile. Move the torch away from the workpiece to make the gouge wider, shallower, and smoother on the bottom. Move the torch closer to the workpiece to make the gouge narrower and deeper.

• You can also adjust the output current of the power supply to change the gouge profile. Decrease the amperage on the front panel to make the gouge narrower and shallower, or increase the amperage to make the gouge wider and deeper.

Any of these techniques can be used to make either small adjustments or significant changes to the gouging outcome. No matter which technique you use, always maintain some distance between the tip of the cartridge and the workpiece. If you move your torch too close, molten metal could splatter onto the cartridge and damage it.

For more detailed information on achieving specific gouging profiles, refer to section 5 of the Powermax SYNC Operator Manual. There is also a 15-degree torch available for gouging applications.

Plasma gouging using Powermax SYNC™ systems delivers smooth, clean, and consistent gouges. Using Hypertherm gouging cartridges makes the process easier. You simply choose the right cartridge for your application and you are ready to gouge. Contact a Hypertherm representative today to learn more.