Infrastructure bill webinar

Power Profits from New Projects with Hypertherm 

When the money from the Infrastructure Investment and Jobs Act (IIJA) finally began flowing into projects, the entities that received funding faced two key challenges: 

  • Skilled labor is hard to find and retain.

  • Inflation pressures have driven up the price of plate, pipe, tube, and beam.

As these entities started new projects, they realized that easy-to-use technologies would be essential for them to preserve and grow business profitability. They needed technology that was easy to learn and use, so they could onboard new hires quickly and effectively.  

Who benefits from IIJA funding? 

Local contractors and engineering firms doing in-shop and in-field work are benefitting from the funding. These firms are cutting, gouging, beveling, and welding for new infrastructure projects that require everything from scrapping to building. Upstream of contractors and engineering firms, heavy equipment manufacturers, metal service centers, job shops, and structural steel companies are also benefitting as are other industries like transportation and shipyards.

Metal cutting in infrastructure 

Cutting is part of the manufacturing process for many infrastructure projects, including building bridges, stadiums, airports, buildings, and ships. Before a metal plate can be bent, rolled, welded, or painted, it has to be cut. Having a reliable cutting method that does not disrupt the value stream is extremely important so cutting does not create a bottleneck and slow production.

Different methods to cut metal 

Different methods to cut metal can be grouped based on technology used.

  • Mechanical – die cut pressing, saw, shear, drill, etc.

  • Thermal – oxyfuel (chemical), plasma, laser

  • Erosive – water jet

Each cutting method has advantages and disadvantages. For example, if you have a high volume, low part deviation cutting requirement, an industrial die cutter could be a great solution for you. However, if you need more versatility and need to cut different sized holes and bevels, then die cut pressing is not the best solution for you.

Why choose plasma for your infrastructure projects? 

Plasma is a mature technology that is well understood and accepted, so people know how it works, how to use it, and how to maintain it. It offers a great balance between high cut quality and productivity, which has a positive impact on overall costs of operations. Plasma also offers great flexibility and versatility.

  • Plasma cuts a wide range of material thickness and metal types. As long as the metal is conductive, plasma will be able to cut it.

  • It performs very well in different applications, including robotic, bevel, marking, gouging, and manual cutting.

  • It delivers excellent cut quality.

  • Plasma is simple to operate and maintain.

If you are building bridges, industrial equipment, buildings, railroads, etc., you will have to apply different cutting techniques like 3D cutting, cutting holes, beveling, and marking. You need a cutting system that can do it all. Plasma can.

Top business objectives in infrastructure 

Key objectives for infrastructure projects include:

  • On-time delivery

  • Increasing efficiency and productivity

  • Improving quality

  • Reducing manufacturing costs

  • Worker safety

While the top business objectives remain the same, difficulty hiring and retaining skilled labor makes meeting these objectives a challenge.

Hypertherm’s response to this challenge? Our consumable cartridges which significantly simplifies the operation and storage needs of the plasma cutters.

Challenges with using mechanized consumables 

Mechanized plasma cutting involves the use of a torch body. At the end of the torch body are small components or consumables. They are installed on the torch and last 3-5 hours of arc-on time, typically one eight-hour shift. Each user will change the electrode, nozzle, and maybe the shield during each shift of mechanized cutting.

Since these parts wear at different rates, operators are changing some consumables, and inspecting all consumables, every day. Consumables need to be installed properly or the torch will not work. They need to be installed in the correct orientation and in the correct order, and they need to have the correct amperages in the stack-up.

This process is time consuming and requires experienced operators. Even with training, there is room for error, including:

  • Consumable errors. It is very easy to make mistakes when installing consumables, which results in damaged plate, blown torches, consumable stack-ups that are blown, unnecessary downtime, and higher costs.

  • Consumable management. If you run two or more processes, you will have 25 or more different consumables that you need to buy and stock in inventory. That is a lot of consumables to stock and manage. There are also many opportunities for mistakes, since it is easy to grab the wrong piece.

  • Poor cutting outcomes. Overused consumables result in bad parts or scrap, sometimes requiring secondary operations to resolve. However, if you replace consumables too soon, that wastes money.

  • Decreased productivity. Some users change processes up to 20 times per shift, going from 80 amp to 130 amp to 260 amp. They have to store used consumables when they switch processes and find those used, but not consumed, parts later when they switch processes again. This process is time consuming and requires managing a lot of partially used consumables.

Hypertherm consumable catridges resolve consumable challenges 

Hypertherm’s single-piece consumable, also known as a cartridge, combines five standard consumables into one cartridge.

This single-piece consumable was designed to wear evenly and is transforming metal cutting.

  • Cartridges can be installed by hand, requiring no tools. You don’t even need to take the torch off the machine to change cartridges, so cartridges extend the life of torches.

  • Cartridges are easy to identify. They are color coded and stamped with the part number and process for easy sorting and storing.

  • Cartridges increase productivity, especially for those doing multiple switches throughout the day. Users simply remove and replace a single cartridge, which takes seconds.

  • They lower operating costs. Cartridges last at least twice as long as copper stack-ups.

  • Cartridges enhance cut quality. Each cartridge comes with all brand-new components that are perfectly aligned, so cut quality remains higher throughout the life of the cartridge.

  • Having only one part to replace is easy for new operators to learn and use. Cartridges take a complicated, labor-intensive, error-prone process and make it easy.

Cartridges help make new infrastructure projects more profitable and easier to handle with inexperienced operators.

Infrastructure applications made easier with Powermax 

Drag cutting

Drag cutting allows operators to drag the torch on the work piece without worrying that the nozzle will get damaged. Drag cutting is much easier for inexperienced operators because you don't need to maintain a distance between the cutting tip and the work piece. It is used for heavy equipment, structural steel, and metal service centers.

Mechanized cutting

Powermax systems can be configured for automation using mechanized or robotic torches. There is a special mechanized shield and mechanized cartridge for this application designed to avoid getting material trapped on the tip of the cartridge and allow for automated equipment to use it.

HyAccess extended consumables

The unique elongated design of the HyAccess consumables allows for better visibility and accessibility when working on challenging cutting or gouging locations. HyAccess extends 3 inches (76mm) beyond standard consumables and is used for cutting tubes and structural steel and in automotive applications.

FlushCut angled consumables

FlushCut enables operators to cut closer to the base material, reducing the need for time-consuming and labor-intensive grinding. An angled nozzle bore directs the plasma arc at 45 degrees. FlushCut is frequently used for lifting lugs that were left behind when moving things by crane. Traditional removal of lifting lugs takes 45 minutes. FlushCut can remove lifting lugs in as little as five minutes.

Max removal gouging 

The max removal gouging process is used for more aggressive material removal and achieving deeper gouge profiles. Max removal gouging is particularly good for repairing heavy equipment used in infrastructure projects, such as removing and replacing wear plates. The alternative to plasma gouging is carbon arc gouging, but that can leave carbon deposits that can make future welds fail.

Max control gouging

The max control gouging process is designed for more precise gouging. It allows the user to control the depth of the gouge profile to achieve shallower profiles and light material removal. It is available for the Powermax45 XP/65/85/105/125. The process is slower, so it is easier for new operators to learn.

Long torch 

Long torches allow users to stand without bending, a tremendous benefit on large jobs. As you build new infrastructure, you often have to remove old facilities, like demolishing an old bridge to build a new one. Long torches are great for decommissioning old plants, cutting up scrap for recycling, cutting materials to turn them into new products, and skeleton removal.

What does the future hold?

As infrastructure spending increases, companies receiving funds need to ramp up operations quickly and effectively. With a tight labor market for welding and cutting, you need to onboard new operators fast and ensure they become productive quickly. Hypertherm’s innovative plasma systems can help. From torches designed to make jobs easier to one-piece consumables that last longer and can be replaced in seconds, Hypertherm delivers the plasma systems you need to get the job done right.  

 

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