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Answers to common questions about single-piece cartridge consumables and adaptors for hand-held plasma torches.
A cartridge is a single-piece consumable that takes the place of the separate parts in a traditional air plasma torch stack, normally the shield, retaining cap, nozzle, electrode and swirl ring. Because it is made as one piece, the parts stay aligned with each other, and fitting it is usually a matter of placing it on the torch and giving it a quarter turn.The main benefits are quick changes and consistent alignment, and because all the working parts wear together you replace the whole cartridge rather than checking each part. Always use the type your torch and plasma system are designed for.
Some modern plasma systems detect that a cartridge has reached the end of its life and stop the arc with a warning, so you do not have to judge it by eye. Not every system or torch combination gives this signal, so check your manual.Most operators change a cartridge sooner, once cut quality starts to fall. Typical signs are a wider, rougher or more bevelled cut, more dross on the underside and slower cutting. Look at the nozzle opening in the cartridge: if it is notched or egg-shaped, replace the cartridge. Do not keep using a worn one, because a failing cartridge can damage the torch itself.
Cutting forces a tightly constricted arc through the metal to separate it. Gouging uses a wider, less focused arc and a torch held at an angle, so the metal is melted from the surface and blown to one side to leave a groove without cutting through. That is why gouging has its own consumables, with a larger nozzle opening than a cutting nozzle.Gouging types usually include a control type for shallow work and beginners, a high-removal type for deep or heavy work, and a precision type for removing small amounts at low current. Many plasma systems have a gouging mode, so check the setting before you start.
A flush cutting cartridge is made for removing attachments such as lifting lugs, pad eyes or temporary weld supports close to the surface of the base metal. Its shield is designed to sit against the plate, and it is intended to leave less material to grind off afterwards than a standard cutting cartridge.These consumables are specific to certain torches and current ranges, and they are not a substitute for a normal cutting or gouging cartridge on other work. Check the manual or parts guide for your torch to confirm compatibility, and use the cutting data it gives.
