Flush cutting

FlushCut consumableClose cutting applications such as lug and attachment removal are typically done using oxyfuel, carbon arc, or traditional plasma cutting tools. New flush cutting capabilities of Powermax® plasma systems offer a safer and more efficient process for these operations by directing the plasma arc at a 45-degree angle from the torch head

Typical flush cutting applications include:

  • Removing lifting lugs, pad eyes and temporary welded supports
  • Light material washing of base plate after cutting
  • End cap removal
  • Welding access hole (“rat hole”) cuts in I and H beams
  • Bolt and rivet removal
  • Casting sprue removal
  • Post tension cable tail cuts
  • Removing work platform/ground attachments

Advantages of flush cutting with plasma vs. oxyfuel

Plasma requires less overall pre-processing time than oxyfuel – no gas setting, purging or preheating – increasing the efficiency of the operation. And, unlike oxyfuel, plasma can remove stainless steel attachments.

In addition, cutting with a Powermax system significantly reduces the heat-affected zone (HAZ) by about 80% as compared to oxyfuel. This is especially useful in flush cutting applications, and provides several important advantages:

  • The ability to safely cut closer to the base material minimizes the need for secondary grinding
  • Cutting closer to the base leaves more of the attachment for reuse, as well as avoiding damage to the base plate.

Comparison of total process time
* Based on lab results

Advantages of flush cutting with plasma vs. carbon arc gouging

Plasma arc gouging product

With carbon arc gouging, the weld on both sides needs to be removed, requiring multiple passes and additional time on the job. A Powermax system allows operators to remove lugs and attachments in a single cutting pass.

Flush cutting with plasma is also a quieter and less smoky process, which can improve the overall industrial hygiene of any shop or yard.

FlushCut consumables

Patented FlushCut™ consumables for Powermax systems have a non-centric nozzle bore design that allows the plasma arc to come out of the torch at a 45 degree angle. This new, patented design lets Powermax users cut closer to base materials. And because of the FlushCut consumables' unique ability to cut so close to base materials, users are more likely to be able to reuse pad eyes, attachments and temporary weld supports.

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New Powermax SYNC series air plasma system from 65–105 amps, featuring single-piece cartridge consumable platform and automated process setup.

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