Flush cutting is an application that typically removes temporary lifting supports, fixtures, or protrusions from the surface without cutting into or damaging the parent metal. Flush cutting is typically done using oxyfuel, carbon arc gouging, or traditional plasma cutting tools. Special consumables are available that direct the plasma arc at a 45° angle from the torch head, making flush cutting with handheld plasma systems especially efficient.
How is plasma flush cutting more efficient than oxyfuel or carbon arc?
How do I ensure the safest flush cutting environment for my operators?
How do I get started with automating plasma flush cutting?
Founded over 55 years ago, Hypertherm Associates proudly brings together centuries of combined application expertise to support cutting professionals worldwide. Let’s tackle your toughest challenges with confidence together. We’re excited to hear from you.
Ask a Cutting ProChoosing the Hypertherm® FlushCut process provides a faster, cleaner, and more precise alternative to traditional methods like oxyfuel and carbon arc gouging. Unlike oxyfuel, which struggles with non-ferrous metals and leaves hard to remove slag, plasma delivers smooth, consistent cuts across a wide range of materials and has up to 10 times less heat affected zone (HAZ). Compared to carbon arc, plasma flush cutting produces minimal slag and debris, reducing the need for grinding. With the ability to cut closer to the base metal, and then plasma washing the residual metal away, FlushCut reduces the need for time consuming and labor-intensive grinding thus helping fabricators to improve productivity and cut costs.
Removing lifting lugs, pad eyes, and temporary welded supports used for material handling — ensures cleaner detachment of handling aids after transport, leaving less surface prep for final finishing or inspection
End cap removal — access to internal components or cavities in piping and structural assemblies, often required during maintenance or retrofitting
Welding access hole (“rat hole”) cuts in I and H beams — provides welders with necessary access to beam flanges for full penetration welds, improving structural integrity and compliance with engineering standards
Bolt and rivet removal — enables efficient disassembly or replacement of fasteners in structural or mechanical systems, minimizing damage to surrounding material
Casting sprue removal — cleans up cast parts by removing excess material from the molding process, ensuring dimensional accuracy and aesthetic quality
Post-tension cable tail cuts — trims exposed cable ends after tensioning in concrete structures, contributing to safety, appearance, and compliance with design specifications
Plasma flush cutting excels in cutting speed, versatility, and edge quality making it ideal for fabrication and manufacturing.
Faster cutting speeds
Cuts significantly faster than oxyfuel or carbon arc, especially on thinner materials and non-ferrous metals.
Versatile material compatibility
Works effectively on a wide range of metals, including stainless steel and aluminum — unlike oxyfuel, which is limited to ferrous metals.
Cleaner edge quality
Produces smooth, consistent edges with minimal slag or dross — reducing grinding or secondary finishing.
Reduced Heat-Affected Zone (HAZ)
Minimizes thermal distortion and preserves material integrity, which is critical for weld prep and structural applications.
Improved safety
Eliminates open flames and carbon arc sparks, reducing fire risk and improving operator safety.
Automation-friendly
Easily integrates with robotic systems and CNC platforms for consistent, repeatable flush cuts in high-volume production environments
Plasma flush cutting is the most efficient and precise method, ideal for fabrication automation, and multi-metal environments
| Feature | Plasma cutting | Oxyfuel cutting | Carbon arc cutting |
|
Cutting speed |
Cuts quickly through thin and medium metals, improving throughput and efficiency | Slower cutting speeds, especially on thinner metals | Moderate speed; faster than oxyfuel on thin metals but less precise |
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Versatility
|
Cuts all conductive metals including aluminum, stainless steel, and copper | Limited to ferrous metals like steel and iron | Works on most metals, especially carbon steel; less effective on nonferrous |
|
Edge quality
|
Produces smooth, precise edges with minimal dross, reducing grinding or other post-processing | Leaves rough edges and slag, often requiring extensive grinding or cleanup | Acceptable for rough work; not ideal for precision cuts |
In the past, whenever this Brazilian petrochemical plant had to remove corroded pipes from its reactors, a full 15-day factory shut-down was required. Today, with Powermax® plasma and FlushCut™ consumables it is possible to do the job without disrupting production.
Petrochemical plant
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For metal workers who want the most versatile system available to gouge, cut, and mark, the Powermax45® SYNC delivers the best return on investment. Part of the Hypertherm® Powermax® family, Powermax45 SYNC features built-in intelligence, a patented single-piece cartridge, and up to 5 times longer consumable life and greater cutting power than higher-amperage competitors.
Professional-grade 20 mm (3/4″) plasma cutter provides automated process set-up and a revolutionary cartridge consumable platform for ease of use and optimized performance. Featuring a wide variety of torches and application capabilities for handheld and mechanized cutting and gouging.
Professional-grade 32 mm (1-1/4″) plasma cutter provides automated process set-up and a revolutionary cartridge consumable platform for ease of use and optimized performance.
Portable, heavy-duty plasma system that maximizes uptime and productivity in handheld and mechanized cutting and gouging operations.
Powermax SYNC plasma cutting systems combine advanced intelligence with a revolutionary single-piece cartridge consumable to simplify setup, reduce operating costs, and enhance cutting and gouging performance. Its color-coded cartridges eliminate part confusion and streamline inventory management, while SmartSYNC® torches automatically adjust settings for optimal operation. With interchangeable torch styles and application-specific cartridges, the system adapts easily to a wide range of tasks. Features like end-of-life detection and extended cartridge life—lasting up to twice as long as traditional consumables—ensure maximum efficiency and productivity.
Typical applications include flush cutting, extended reach cutting, drag cutting, bevel cutting, gouging, and fine feature cutting.
Patented FlushCut™ consumables and cartridges 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, allowing for lugs and attachments to be removed with a flat bottom, increasing the chances for the lug or attachment to be reused. The angled nozzle bore design and flat guiding shield enable flush cutting that leaves less than 5 mm (3/16 in) residual material on the base or workpiece, reducing grinding and secondary repair operations.
With simple, twist-on consumable installation and convenient power and amperage adjustment controls on handheld models, SmartSYNC® torches for Hypertherm Powermax45/65/85/105 SYNC® plasma systems, and Powermax45® XP with adapter, allow the operator to change consumables and applications without returning to the power supply. This reduces consumable change time to about 10 seconds and automatically sets up the system for the cartridge, minimizing downtime, troubleshooting, waste, and training time.
