Skip to content

Module 2: Material Science & Cut Parameters

Overview

This module focuses on the physics of material-specific cutting and the parameters that control cut quality. Students will understand how material properties (conductivity, melting point, thermal conductivity, oxidation tendency) affect cutting behavior, interpret and apply cut parameter tables, select amperage and cut speed for given materials and thicknesses, and assess cut quality using visual and measurement criteria.

Learning Objectives

  1. Explain how material properties affect plasma cutting behavior
  2. Interpret cut parameter tables and apply them to new materials/thicknesses
  3. Select amperage for given material and thickness
  4. Calculate and set cut speed based on parameters
  5. Assess cut quality using visual inspection and measurement criteria
  6. Explain the relationship between cutting parameters and dross, bevel, kerf width

Module Structure

  • Slide 1: Metal Conductivity & Plasma Cutting Behavior
  • Slide 2: Material Types & Cut Quality (Steel, Stainless, Aluminum)
  • Slide 3: Thickness & Amperage Selection
  • Slide 4: Cut Speed & Quality Trade-offs
  • Slide 5: Cut Quality Assessment & Inspection Criteria

Assessment

  • 10-question module quiz (parameter selection and quality assessment)
  • Hands-on: Cut samples and evaluate quality
  • Activity: Create cut parameter procedure for new material

Time Allocation

  • Instructor Delivery: 4 hours
  • Guided Activities: 2 hours
  • Self-Study & Assessment: 1 hour
  • Total Module Time: 7 hours

Key Standards Referenced

  • ANSI/AWS C4.1-2012: Recommended Practices for Plasma Arc Cutting
  • AWS A3.0: Specification for Welding Procedure and Performance Qualifications

Prerequisites

  • Module 1: Plasma Arc Technology (understanding arc physics, consumables)
  • Basic metallurgy: familiarity with metal types and properties

Resources

  • OEM cut parameter tables for your specific system (must be calibrated for your equipment)
  • Material property reference sheets (thermal conductivity, melting points, electrical conductivity)
  • Cut sample set (steel, stainless, aluminum at various thicknesses)
  • Measuring tools (digital caliper, thickness gauge)
  • Visual inspection guide (examples of acceptable and unacceptable cuts)

Module Version: 1.0 Created: 2026-03-15