One of the advantages of the Powermax45 XP is its efficiency...It gets the molds quicker back into production and makes it easier for me to gouge...”
Nordland Betong
Steel service center
Read moreEnhance safety and productivity with plasma arc gouging
Plasma gouging removes unwanted metal or welds using a plasma arc between the torch and the workpiece, melting the surface, then blowing it away with high-pressure gas, often air. The gouging process can be done manually using a handheld torch or automated with the use of industrial robots, cobots, XY / gantry, and fixed torches. A variety of gouging consumables are designed to produce different types of gouge contours and material removal rates.
No matter your gouging challenge—let’s gouge together!
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Which gouging technique should I use?
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How do I ensure the safest gouging environment for my operators?
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How do I get started with automating gouging?
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Ask a Cutting ProOverview
While many shops, production floors, and training facilities routinely use carbon arc gouging, they live with its shortcomings every shift: extreme noise, hazardous fumes, and grinding for weld prep, to name just a few.
There's a better way.
Switching to plasma arc gouging will likely improve operations and the bottom line. Plasma arc gouging offers a safer and healthier work environment and yields consistent and cleaner gouges, reducing the need for secondary operations and increasing productivity.
Benefits of plasma arc gouging over carbon arc gouging
Achieve consistent and cleaner gouges, reduce the need for dangerous secondary grinding operations, and get better results by switching to plasma gouging.
Plasma gouges with lower noise and fume emissions
In many cases, plasma gouging is 5 to 10 decibels quieter. With less dust produced, it reduces slip hazards. The sparks are not blown as far and burn out quickly, thereby reducing fire hazards. Carbon arc gouging is noisier and generates potentially hazardous smoke and fumes, posing a risk to workers.
This often makes plasma gouging a safer and more environmentally friendly choice for indoors or confined workspaces.
Plasma gouges can be more precise and cleaner
Plasma gouging can produce, especially in automated applications, a more controlled contour, resulting in less post-processing work such as grinding. Carbon arc gouging leaves slag that is very difficult to remove.
The precision of plasma gouging helps improve workflow efficiency and reduces labor costs.
Plasma gouges with little to no contamination
Plasma gouging does not use carbon electrodes, eliminating the risk of carbon contamination in the base material. Carbon arc gouging requires extensive secondary operation before welding due to the removal of carbon embrittlement introduced into the base material.
Plasma gouging delivers stronger welds and better overall material integrity.
Plasma gouges a greater range of materials
Plasma arc gouging is effective on a wide range of metals, including abrasion-resistant steel, stainless steel, aluminum, and other non-ferrous metals. Carbon arc gouging is not effective on non-ferrous materials.
This versatility makes plasma gouging ideal for industries working with diverse metal types.
Plasma gouging is highly compatible with automation
Plasma systems are easier to integrate into a track-guided motion system, cobot, or robotic system, making them ideal for automated or high-precision applications. Carbon arc gouging is difficult to automate, and results are inconsistent.
Plasma's automation compatibility supports scalable production and consistent quality in manufacturing environments.
Plasma vs. carbon gouging at a glance
| Features | Plasma Arc Gouging | Carbon Arc Gouging |
| Noise and fumes | Lower | Higher |
| Mechanical precision | Higher | Lower |
| Contamination risk | Lower | Higher |
| Material compatibility | Wide | Limited |
| Automation | Easily automated | Very challenging |
| Secondary operations | Minimal | Extensive |
How plasma arc gouging is used in some industries
Plasma arc gouging is a powerful tool for fast, precise metal removal—and it’s making a significant impact across several heavy industries. Here’s how it helps:
Shipbuilding and marine repair
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Remove corrosion and old welds quickly and cleanly
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Work efficiently in tight or outdoor spaces, like ship interiors or docks
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Speed up repair in weld defects with less grinding and prep work
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Enable full penetration welds with precision via back gouging to remove material to the root welds
Heavy equipment
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Repair worn components like buckets, blades, and frames
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Perform hardface removal on buckets, teeth, and other components, including wear plates
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Handle tough materials used in construction and mining
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Save on costs by reworking instead of replacing parts
Rail repair and maintenance
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Maintain railcars and tracks with fast weld and defect removal
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Minimize downtime with less surface prep
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Use in the field thanks to portable, rugged equipment
Structural steel
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Remove or rework welds on beams, joints, and columns
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Perform back gouging of linear welds
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Maintain structural integrity with precise gouging
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Adapt to various steel types and thicknesses
Hypertherm plasma gouging solutions
Plasma arc gouging is a fast, precise way to remove metal—and it’s a game-changer in a variety of repair and fabrication tasks. Here’s how plasma arc gouging helps in some of the most common applications:
Back gouging with plasma ensures full weld penetration by removing material from the backside of a joint. Back gouging with plasma provides structural integrity, works great on thick materials, and is cleaner and faster than traditional grinding.
Weld removal with plasma arc gouging removes cracked or defective welds to prep for clean, substantial rework. Plasma delivers smooth, precise gouging for easy re-welding, less heat distortion than other methods, and improves repair quality and inspection readiness.
Riser and sprue removal of cast parts is something plasma arc gouging excels at. It quickly removes excess metal from cast parts without damaging the surface. Plasma gouging enables clean, controlled riser and sprue removal, is faster than grinding or machining, and protects part integrity for better finish and performance.
Hardfacing removal with plasma arc gouging strips away tough, wear-resistant coatings before repair or reapplication. Plasma gouging handles hard alloys with ease, reduces tool wear compared to mechanical methods, and speeds up prep time for re-hardfacing.
Compare plasma vs. carbon arc gouging
Learn why plasma arc gouging is often more desirable for industrial applications than carbon arc. Plasma arc gouging offers greater precision, faster metal removal rates, and less contamination compared to carbon arc gouging. It also produces less noise and smoke, making it more suitable for cleaner and more controlled environments.
Powermax systems – versatile and portable
The Powermax® family (Powermax45 SYNC, 65 SYNC, 85 SYNC, 105 SYNC, and 125) offers portable, air plasma systems that excel at both cutting and gouging.
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Multiple gouging modes: Max Removal, Max Control, and Precision Gouging
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Easily switch between cutting and gouging by changing the consumables
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Perfect for field work thanks to rugged design and portability
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Compatible with a wide range of torches and consumables, including Max Control, and Max Removal, for different applications
MAXPRO200 – heavy-duty performance
The MAXPRO200® is built for high-capacity, industrial gouging and cutting. It’s ideal for applications that demand long duty cycles, deep gouging, and high productivity.
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High amperage output (up to 200 A) for aggressive metal removal
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Consistent arc quality for smooth, clean gouges
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Durable and reliable in demanding environments like shipyards and heavy equipment repair
Explore gouging products
Powermax45 SYNC plasma cutter
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.
Powermax105 SYNC plasma cutter
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.
MAXPRO200 plasma cutter
Dubbed the industry workhorse because of its power and 100% duty cycle, the MAXPRO200® plasma cutter is designed for your heavy-duty, high-capacity automated and handheld cutting and gouging applications. MAXPRO200. Get work done.