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Plasma torch spares for one maker's cutters: how to match the right part, spot wear and fit it safely.
The electrode carries a small insert at its tip that burns away a little with every start. As it wears, a pit forms in the centre, and the cut quality usually falls. Misfires or a hesitant pilot arc can also point to a tired electrode.Look at the tip under good light. If a clear cavity has formed, or the manual shows a limit for pit depth, replace it. The permitted depth differs between torches, so use the figure in your manual rather than a rule of thumb. If the electrode has worn out because of the insert, the matching nozzle is usually changed at the same time.
The nozzle focuses the arc through a small round hole. Signs of wear include erosion around the hole, a hole that is no longer circular, blocked gas holes and damaged O-rings on the outside.On the cut itself, a worn nozzle usually gives a wider kerf, more dross on the underside and a bevelled or ragged edge. If cut quality drops and nothing else has changed, inspect the nozzle and electrode together. A damaged nozzle should be replaced, not cleaned up and refitted, because the hole shape controls the arc.
Only a very thin film of the silicone lubricant recommended in your manual, and only on O-rings that look dry. A correctly lubricated O-ring has a slight shine.Too much grease can block gas passages, attract metal dust and lead to poor arc behaviour or damage, so wipe off any excess with a lint-free cloth. Do not grease the threads or the torch body unless the manual says so. If an O-ring is worn, split or flattened, replace it instead of trying to rescue it with more lubricant.
A gouging nozzle is made for removing metal, such as taking out a weld or a defect, rather than cutting through the plate. It usually has a larger bore than a cutting nozzle, which gives a wider, softer arc, and the torch is held at a shallow angle so the metal is blown out as a groove.Cutting nozzles give a narrower, more focused arc to sever the plate. Many cutters have a gouging mode that adjusts the settings, so use it where the manual says. Current mainly affects how wide and deep the groove is. Do not swap the two types around; fit the parts your manual lists for each job.
