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Straight answers to the questions people ask most when choosing and using a plasma torch consumable kit.
A kit groups together the wearing parts of a hand plasma torch so you can change them in one go. Typically that means electrodes, nozzles (also called tips) and a swirl ring, often with a shield or drag cup and sometimes O-rings and a small tube of silicone grease.Contents differ from kit to kit, so check the parts list against your torch manual before you rely on it. A kit is usually matched to a particular torch and cutting current, not to every torch.
The electrode and the nozzle do most of the work. The electrode carries the current and the arc starts from a small insert in its tip, which erodes as you cut. The nozzle squeezes the arc into a narrow jet, and its hole slowly wears larger or out of round.The swirl ring and shield cup last longer but are not permanent. They need replacing when damaged, for example chipped, cracked or with blocked gas holes. The manual for your torch shows each part and what to look for.
A new electrode in a worn nozzle, or the other way round, usually cuts poorly and may wear faster. Many suppliers advise changing both together, because the two wear as a pair and their fit affects the arc. Some torch makers instead say to inspect each part separately and replace whichever shows wear, so follow your own manual.Either way, a matched set of parts is useful to have ready. If you want to stretch the life of a set, do it by cutting well, piercing at the right height and keeping the air clean and dry, not by running worn parts.
Start from the torch model and the cutting current you actually use. Consumables are rated for a maximum current, and parts rated below the current you set will wear out very quickly. Parts for different torches often look alike but do not interchange.Read the part numbers or descriptions on your torch's consumables chart in the manual, and match the kit to those. If you cut at more than one current, you may need more than one set of nozzles. Our team can help you match a kit to your torch.
Look at them each time you change parts. An electrode is worn when the insert in its tip has burned away into a pit or hole; the exact depth that counts as worn depends on the maker, so follow your manual. A nozzle is worn when the hole is enlarged, oval or has damaged edges, or when its seals are damaged.On the cut itself, the usual signs are a rougher edge, more dross, a wider kerf, a hard-starting or wandering arc and a bevelled edge. If you see these, inspect the consumables before changing any settings.
The three biggest factors are travel speed, current and torch height above the work, and the condition of the consumables also counts. Cutting too slowly leaves thick globs of dross on the underside, cutting too fast leaves a hard bead, and a worn nozzle is a common cause of both bevel and dross.Check the nozzle first. If it is worn, change the electrode and nozzle as a pair. Then check that the torch is square to the work and that your speed and height match the cut chart in the manual.