Newbie Questions - Cutting Light Gauge Aluminum

[brucew]

I am new on the forum, and would be appreciative of some insight into the subject of using a plasma cutter on light gauge aluminum sheet 32 thou and 25 thou T6 6061 used for building aircraft. 3 questions.

Will plasma give me the accuracy? hole centers need to be within 20 thou across 10' lengths?
Will it be suitable to cut large volumes of small (1/8" diameter) holes at 1 1/2" centers for a 10' length?
Will it warp the material?

[Kentuckyfarmer]

IMHO all 3 are more dependent on the accuracy of the table, what brand or size table do you have?

[WSS]

Will plasma give me the accuracy? hole centers need to be within 20 thou across 10' lengths?
Will it be suitable to cut large volumes of small (1/8" diameter) holes at 1 1/2" centers for a 10' length?
Will it warp the material?

You will not get clean holes at that size, probably accurate on centers but not too round.

WSS

[Scratch]

I don't think it's the accuracy of the table you need to worry about... The accuracy of the Plasma Cutter is going to be your problem...

[redneckgateart]

I agree...with holes that small, you're probably not going to be happy. You could always rig up a small spindle (drill/router) on your z azis(along with your torch) and drill the holes, rather than torching them....ie. drill the holes, then cut the outlines. Assuming that your table is accurate enough, you'll probably be satisfied with the end result. The thin aluminum is going to warp as you cut it but it should lay back down as it cools.

Even if the plasma holes were "round enough", I think there's going to be a lot more de-burring involved, especially if you plan on rivetting the panels.

Just my 2 cents.

[brucew]

Thanks all for the advice, confirms my suspicions.

[jimcolt]

Water jet is often the best choice for aircraft components as there is no thermal stress involved. Laser and plasma are not the best.

Jim