10 Gauge Aluminum Settings

[tnbndr]

First time trying to cut aluminum.
Did test cut with book specs and got tons of dross but cut through.
Got best cut with settings in photo, but still more dross than I thought would be there. Is anyone cutting aluminum with a PM45 dross free that can share their settings. Kerf width, voltage, speed, etc.
All the parts came apart but quite a bit of dross.

[jimcolt]

First, make sure your real time cut height is .06".....adjust your preset voltage until it is right. Next, there are a lot of different grades of aluminum...speed is the key to dialing each one in. My first guess is faster...so do a series of simple straight lines increasing the speed 20 ipm each time...eventually the dross should be minimized. Last, you may need to lower the water. I cut 10 gauge aluminum on my downdraft table dross free at the Hypertherm book specs. The specs were developed with dry, downdraft fume control.

Jim Colt Hypertherm

First time trying to cut aluminum.
Did test cut with book specs and got tons of dross but cut through.
Got best cut with settings in photo, but still more dross than I thought would be there. Is anyone cutting aluminum with a PM45 dross free that can share their settings. Kerf width, voltage, speed, etc.
All the parts came apart but quite a bit of dross.

[tnbndr]

Thanks Jim, I will try with the water lower and more speed.
Am I right to assume the Kerf width means nothing in SheetCam other than that is what is used to calculate the correct offset if used?

[jimcolt]

Yes, the software offsets the cut using the kerf width you set...in order for the part to be sized correctly. Cutting slower makes a wider kerf, higher cut height makes it wider, more amperage and larger nozzle orifice makes tha cut wider.

Jim Colt Hypertherm

Thanks Jim, I will try with the water lower and more speed.
Am I right to assume the Kerf width means nothing in SheetCam other than that is what is used to calculate the correct offset if used?

[dhelfter]

tnbndr,
I noticed your tool settings you have no dthc? Have you tried to cut with thc on?

Dan
LDR

[tnbndr]

Dan:
Yes, I had it off for the test cuts, just lines, but turned it on to do the actual cuts.! I think! I have to look now but that was my intention.

[Largemouthlou]

Did you ever get this straightened out? I cut a lot of .125 aluminum, but I'm running a 1250 with a duramax retro fit.
I just recently put the duramax on so still tweaking but the book specs were right on to get started. Not sure why yours would look like that.

Im using the 45 amp tip at 45 amps 100 ipm .060 pierce 1500 and .065 for kerf 140 volts

10 guage is .1406
12 guage .s .125 which is what I cut.

Just relooked at your speed (ipm) seems very high

[tnbndr]

Book spec for the PM45 is 220ipm, so I am a little slower.
Have not dialed it in yet.

[tnbndr]

Trying this again.
Switched to book specs for PM45. New electrode, new nozzle.
Lower left in pic is the result of book specs, lower right is without DTHC and upper right is at a slower speed with DTHC.
It seems the DTHC is raising to high and not allowing a complete cut after the pierce.
I have verified that the cut height is .060. Tried with water low, no difference.
Anyone using a PM45 to cut 10 gauge aluminum nicely?

[tnbndr]

Ended up cutting with DTHC off and got nice cuts after I dialed in the voltage and speed.
As soon as I turn on the DTHC it seems to surge all over looking for the right height to cut and then it doesn't cut through.

[SeanP]

Ended up cutting with DTHC off and got nice cuts after I dialed in the voltage and speed.
As soon as I turn on the DTHC it seems to surge all over looking for the right height to cut and then it doesn't cut through.

That doesn't sound quite right, did you take a note of the voltage when you were cutting with dthc off? was it anywhere near your preset when you had it turned on?

I did a bit of 6mm chequer plate the other day, it cut fairly well I thought, this was just a tester I did to get torch volts setting.

2100mm/min
115v

It was 6mm to the top of the markings, cut smooth side up, no clean up there.

[tnbndr]

That doesn't sound quite right, did you take a note of the voltage when you were cutting with dthc off? was it anywhere near your preset when you had it turned on?

Yes, I cut test lines about 12" long and note the steady voltage and that is what I use for the preset when I turn the DTHC on. But it doesn't work right.
It works fine on steel. That is why I am puzzled.

[SeanP]

I had similar problems today cutting 3mm, it was a lower grade ally not sure which though, mine would cut a good distance ok (4' or so) thc looke dto be working fine then it started lifting away from the plate, I kept lowering voltage on the fly which did lower the torch but had to keep doing it to finish the cut.
I did up the thc rate to 30% I was at 28%, it did seem ok after that.
I cut some 3mm marine grade ally the other week that cut great.
Did you suss out your problems eventually tnbndr?

[tnbndr]

Did you suss out your problems eventually tnbndr?

SeanP, I never really did figure anything out for certain. I don't cut a lot of aluminum and when I do it is hit or miss. I believe it is just the vast amount of different alloys available and when I get an ally job it is usually a piece supplied by someone else that had it laying around or bought a cutoff but what alloy is it is anyones guess.
I just do a couple of test lines if I have room and go from there.

[SeanP]

Good stuff, same here I don't cut much ally, I had to cut way slower than book for that 3mm I had to drop to around 4250, book looks like 6250mm.

Did you suss out your problems eventually tnbndr?

SeanP, I never really did figure anything out for certain. I don't cut a lot of aluminum and when I do it is hit or miss. I believe it is just the vast amount of different alloys available and when I get an ally job it is usually a piece supplied by someone else that had it laying around or bought a cutoff but what alloy is it is anyones guess.
I just do a couple of test lines if I have room and go from there.

[jimcolt]

If the DHC (height control) is not maintaining the correct physical cut height (which is .06" for 10 g aluminum with a Powermax45 (using the machine torch shield)...then you are not at book specs.....which will explain the ugly cuts. I stand 100% behind the book specs on the cut charts in the Powermax45 operators manual....though on some grades of aluminum you may need to increase or decrease speed slightly. Cut height is the most important parameter. If the height is varying...then solve the height control issue in order to make your cut quality consistent.

I cut aluminum often....it cuts different than steel, but very clean and very minimal soft dross.

Jim Colt Hypertherm

[tnbndr]

Cut height is the most important parameter. If the height is varying...then solve the height control issue in order to make your cut quality consistent

Jim:
I completely agree with your statement. I wish I had taken a video of this being cut. As it was cutting the torch was moving up and down like a freaking roller coaster. All settings were at book spec, that is why I posted originally and was completely surprised..
I have cut some other aluminum since with no issues, so I think it was some weird alloy or the stars were not aligning. But it always makes me leary when someone wants aluminum.
Next quest is cutting some copper!!!!