A 45 to 50 amp plasma cutter that has a rated load voltage of approximately 130 or more arc volts (multiply the amperage output x the manufacturers rated load voltage), so say 45 amps x 132 volts = 5940 watts, or roughly 6.0 killowatts will cut and pierce 1/2" steel all day, can sever as much as about 1-1/4" if you have a steady hand. Above about 1/2", or maybe 5/8" you would be advised to edge start as piercing thicker than that with this power level could damage the nozzle and shield, which would then affect subsequent cut quality.
The load voltage is generally listed by major manufacturers, and is the voltage that the unit can produce at its rated duty cycle at a 104 degree ambient temperature. Some suppliers choose to rate their systems by amperage alone, without listing load voltage....not sure why!
A Hypertherm 45 amp unit will offer a set of lower amperage consumables if you are looking for detailed cutting with a very fine, narrow kerf on thin materials, will also offer the shielded 45 amp consumables that allow drag cutting, template cutting and straightedge cutting without allowing double arcing to the material (this happens when an exposed nozzle on an unshielded torch touches the material being cut), and creates "stiction" (torch sticks to the plate) and short nozzle orifice life. Most just use the 45 amp shielded nozzle for all cutting jobs. There also is a gouging nozzle, specially designed to produce a lower energy density wider arc for removing welds efficiently...great for disassembly type work. The unit has a selector switch with modes for cutting expanded metal (the unit rapidly switches from cutting power to low pilot power in a few miliseconds) so the the arc stays on when crossing the void or holes in expanded metal. Many plasma's will do this, at the expense of nozzle life, the selector switch also has a gouging mode which uses different air flow and power supply technology to be most efficient in terms of metal removal rate when gouging.
Consumable life and cut quality is the technology that Hypertherm products are built on. You will pay more for a Hypertherm nozzle and electrode (consumables) but you will find they last 6x to 10x longer than other systems. I suggest doing some internet searching to see what actual users say about the cut quality and consumable life....as the same performance is often claimed by other manufacturers. Higher purchase price for dramatically longer lasting consumables pays off with lower cost per foot of cut.....basically if you keep the unit and use it...it will be less expensive (compared to others) the longer you own it, the more you use it.
If you compare the real cut speeds between a 45 amp Hypertherm and most 60 amp competitive units...you will find they are similar....partly due to the higher kW output, partly due to torch technology called conical flow....which uses the shield gas and the design of the nozzle and shield to increase energy density after the plasma arc is formed. Torch technology is always up to date on Hypertherm products, as all torches are designed engineered and manufactured by us.
Further, the operators manual for a Hypertherm can have as many as 100 pages, maybe 20 are just cut charts with cut kerf dimensions, cut speeds, amperage and techniques for cutting about anything. Pages on systems maintenance, troubleshooting, gauging consumable wear are in there, and there is also another (freely downloadable) technical manual to help you maintain the plasma long term....right down to internal voltage and troubleshooting tests to determine the best next step when repairs are needed.
So, all plasma cutters will cut metal. Ours are designed to cut metal reliably, for many years, and with the lowest operating cost possible. I suspect that all of this will get challenged on this thread....and I won't get into the nitty gritty on every point. There is a reason why users spend 2 or more times more for the higher end major brand plasma cutters.....if they were the same in terms of reliability, cut quality and operating cost...then we would not be in business.
Best bet is to put the torch in your hand a cut with it. Then cut with other brands and models. The offer is open to come to my home shop and cut with a 30 amp, a 45 amp and an 85 amp Hypertherm, try the gouging, try the Finecut consumables.
Jim Colt
Most of the stuff I would be cutting would be 1/4" or less. Occasionally up to 3/4"... But I've been getting by with grinders, a cut off saw and sawzall. Don't see myself cutting anything bigger. I might use it 1-2x a week or not at all for a couple months.
I do have a 1 1/4" footplate that I want to cut off so I can I have a wedge on beam splitter.
I imagine 45-50 amps would do everything I want but could probably be happy with 30...
So, what would the hypertherm do for me that a everlast or harborfreight plasma won't?
And mark, how do you know which power plasma 50's are there latest design?
