HyperTherm sync powermax 65 Cuts

[MikeTRD]

Can anyone help me with settings for a Powermax sync 65 plasma cutter. i want to use the fine cut 45a heads on aluminum. can anyone share their thoughts and ideas on the matter. my aluminum cuts come out okay with the reg 45 amp tip. but want them to way better and have no dross on them.

[weldguy]

I would do some straight line test cuts. With each line you cut i would increase the speed until I find it’s moving too fast and then back it off a little. This should help with your dross if its thinner material. What thickness are you cutting?

[MikeTRD]

.032, .060, .090 .125

[MikeTRD]

what setting do i use, and can i use a fine cut on aluminum?

[acourtjester]

this is from the manual, no fine cut on aluminum.

[caretech]

What thickness of aluminum are you cutting? I think I've used fine cut on up to 3/16.

My experience is that cutting aluminum on air plasma is simply not going to be a good experience. There's a bit less dross with fine cut but you still need to do a lot of cleanup if you want your edges to look nice. Lots of alum flap disk work to do. Ultimately I wish I'd have a laser but that needs to wait...

I talked to my gas supplier about using nitrogen in my powermax 85 and his comment was don't bother, it's too expensive. I didn't push it further just yet, but I am curious what cut results could be had feeding nitrogen instead of air for cutting aluminum. Curious if anyone here has tried it and how it worked for you.

[weldguy]

.032, .060, .090 .125

All those thickness' should cut very easily, very clean, with little to no dross if you have your cut height and cut speed correct. The straight line tests cuts are the best way to determine the best speed and jot those settings down for next time.

what setting do i use, and can i use a fine cut on aluminum?

Yes, you can use fine cut on aluminum. Start with the setting in the mild steel chart since there is no chart for aluminum and start doing the straight line test cuts. Pause the machine mid-cut and measure the torch to material distance with feeler gauges to be sure it is correct. If y9ou find yourself increasing the speed to eliminate dross be sure to check your torch to material distance again since it can change with speed.

The thicker the aluminum you are cutting the more difficult it is to eliminate the dross but everything your cutting should cut clean.

[SegoMan DeSigns]

this is from the manual, no fine cut on aluminum.
45 shielded Aluminum.JPG
45 unshielded Aluminum.JPG

Tom,

Your chart is for the std Duramax torch / consumables

Here is the link to the Sync charts:

https://www.plasmaspider.com/download/c ... Charts.pdf

[mechanicjon]

100% Argon gas will give you a lot better cut.