Flush cutting is an application typically used to remove attachments, protrusions, or fixtures from the surface of an otherwise flat base material, without cutting or damaging the overall surface. Flush cutting with handheld plasma systems is done efficiently using special consumables that direct the plasma arc at a 45° angle from the torch head.
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
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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The Powermax45® XP 45-amp plasma power supply was last manufactured in March 2024, and is no longer available for sale from Hypertherm. We continue to make original replacement torches, consumables, and repair parts.
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.
Portable, heavy-duty plasma system that maximizes uptime and productivity in handheld and mechanized cutting and gouging operations.
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.