Plasma Electrode

Electrodes in high-power plasma cutting systems are carefully designed consumables that are similar in design, material and function to spark plugs in automobiles. Similar to a spark plug, the electrodes emit high-voltage electrons in a high temperature environment. Therefore, the materials used must be able to withstand high temperature plasma arcs, withstand high pressure vortex jets and provide a reliable seal to ensure that high pressure gases and liquids do not seep out. Electrodes, like spark plugs, are the harshest parts of the system.

The electrodes deliver the direct current output from the plasma power source to the sheet metal. The electrode typically contains a copper or copper/silver composite holder containing the readily electron-emitting element hafnium, a high melting point metal that sustains the plasma arc in air and oxygen cutting environments. This electron-emitting element slowly corrodes under the heat of the arc and the high-pressure plasma gas flow. Most of this wear occurs at the start and stop of cutting, when the molten hafnium material heats and cools, causing it to melt and then resolidify.

During normal wear, a small dimple is formed at the end of the electrode, which wears steadily, a few thousandths of a centimeter at a time, until a dimple is formed to a depth of 0.040 to 0.125 cm, depending on torch and wear The design and material of the pieces. When the dimples get too deep, the arc attaches to the retainer material and melts it. Electrodes "fail" when they can no longer generate and sustain an arc. If molten electrode material sinks into the nozzle hole, it will cause "scrap," a catastrophic failure for both the electrode and the nozzle.

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