What Can’t Be Cut with a Plasma Cutter?

What Can’t Be Cut with a Plasma Cutter

Plasma cutters are powerful tools used to cut through various types of metal, but they do have their limits.

Some materials can’t be cut with a plasma cutter due to safety concerns or the physical properties of the material. For example, very thick metals, certain types of metal with high reflective properties like aluminium, and non-conductive materials like wood or plastic are not suitable for plasma cutting.

In this article, we’ll explore the materials that are not compatible with plasma cutting, the reasons behind these limitations, and some alternative methods for cutting materials that plasma cutters can’t handle.

Understanding these boundaries will help you use your plasma cutter safely and effectively whether you’re a professional or a hobbyist.

Thanks for reading!

The Power of Plasma Cutting

Plasma cutting is a remarkable process that has revolutionized the welding industry. It’s a technique that harnesses the incredible power of ionized gas, commonly referred to as plasma, to cut through various materials with precision and speed.

At its core, plasma cutting involves creating an electrical channel of superheated, electrically conductive gas. This ionized gas, in its fourth state of matter (plasma), can reach temperatures of up to 30,000 degrees Fahrenheit (16,649 degrees Celsius).

The process begins with a stream of compressed air or other gases passing through a small nozzle. An electrical arc is then introduced to the gas, causing it to ionize and form the plasma arc.

The intense heat generated by the plasma arc melts the material being cut, while a high-velocity jet of gas blows away the molten metal, leaving behind a clean and precise cut.

This ability to melt and remove material quickly and cleanly is what makes plasma cutting such a valuable tool in the welding industry.

Plasma cutters are prized for their versatility. They can effortlessly slice through a wide range of materials, from thin sheets of metal to thick steel plates.

  1. Mild Steel: Plasma cutting is exceptionally efficient when it comes to mild steel, making it a popular choice for welding and metal fabrication projects.
  2. Stainless Steel: The precision of plasma cutting is ideal for stainless steel, ensuring clean cuts without warping or distortion.
  3. Aluminum: Plasma cutters can handle aluminum with ease, providing smooth edges and minimal cleanup.
  4. Copper and Brass: These materials, known for their high electrical conductivity, are also suitable for plasma cutting.
  5. Expanded Metal: Plasma cutters are adept at cutting expanded metal, a material frequently used in construction and industrial applications.
  6. Non-Ferrous Metals: In addition to ferrous metals like steel, plasma cutters can also work effectively with non-ferrous metals like copper, brass, and aluminum.
  7. Conductive Metals: Materials that can conduct electricity, such as various metals, respond well to plasma cutting.

Limitations of Plasma Cutting

Plasma cutting is undeniably a versatile and potent tool, but like any other technology, it has its constraints. Understanding these limitations is vital for welders, especially those who are just starting their journey into the world of welding and metal fabrication.

Factors Determining What a Plasma Cutter Can’t Cut:

  1. Thickness of the Material: While plasma cutters can handle a wide range of material thicknesses, extremely thick materials may pose challenges. The limitations can vary depending on the power of the plasma cutter. For exceptionally thick steel plates, alternative cutting methods like oxy-fuel cutting may be more suitable.
  2. Material Conductivity: Plasma cutting relies on the ability of the material to conduct electricity. Non-conductive materials, such as wood or plastic, are not suitable for plasma cutting as they cannot establish the necessary plasma arc.
  3. Material Composition: The chemical composition of the material plays a significant role. For instance, materials containing a high degree of reflective elements like copper or aluminum can be difficult to cut with a plasma cutter due to their tendency to dissipate the energy of the plasma arc.

Practical Limits of Plasma Cutting, Especially for Beginners:

  • Thin Materials: While plasma cutters are versatile, they may not be the best choice for cutting very thin materials. In such cases, the intense heat of the plasma arc can lead to excessive warping or damage.
  • Intricate Designs: Achieving intricate, detailed cuts can be challenging, particularly for beginners. Precision work often requires a steady hand and practice to master.
  • Consumable Parts: Plasma cutters have consumable parts like electrodes and nozzles that wear out over time. Beginners should be aware of the maintenance requirements to ensure consistent cutting performance.

A few examples to give you a better understanding.

  1. Refractory Metals: Tungsten and molybdenum, known for their exceptionally high melting points, can be extremely resistant to plasma cutting due to their refractory nature.
  2. High-Reflectivity Materials: Copper and aluminum, which reflect heat and energy, can be challenging to cut with a plasma cutter. The reflective properties can dissipate the energy of the plasma arc, leading to incomplete cuts or uneven edges.
  3. Non-Conductive Materials: Plasma cutters are designed to work with conductive materials. Attempting to cut non-conductive materials like wood or plastic can damage the workpiece and the cutter itself.

Alternative Cutting Methods

When you encounter materials that resist the power of a plasma cutter, it’s essential to have alternative cutting methods at your disposal. Each of these methods comes with its own set of advantages and disadvantages, making them suitable for different scenarios.

Oxy-Fuel Cutting

Oxy-fuel cutting is a traditional method that uses a combination of oxygen and a fuel gas (typically acetylene) to generate a high-temperature flame.

  • Advantages:
    • Well-suited for thick materials, including steel plates.
    • Effective for cutting through materials that resist plasma cutting, such as refractory metals.
    • Relatively low equipment cost compared to some other methods.
  • Disadvantages:
    • Slower cutting speed compared to plasma or laser cutting.
    • Limited precision, making it less suitable for intricate designs.
    • Produces a heat-affected zone (HAZ), which may require additional post-cutting work.

Laser Cutting

Laser cutting utilizes a focused laser beam to melt, burn, or vaporize the material being cut.

  • Advantages:
    • Exceptional precision and accuracy, making it suitable for intricate designs.
    • High cutting speed, making it efficient for a wide range of materials.
    • Minimal material distortion or warping.
  • Disadvantages:
    • Higher equipment and maintenance costs.
    • Limited thickness capability compared to oxy-fuel cutting.
    • Some materials, like highly reflective metals, may require special equipment.

Water Jet Cutting

Water jet cutting uses a high-pressure stream of water mixed with abrasive particles to erode the material.

  • Advantages:
    • Versatile and capable of cutting a wide range of materials, including metals, ceramics, and composites.
    • No heat-affected zone, making it suitable for materials sensitive to heat.
    • Minimal environmental impact due to the absence of hazardous fumes.
  • Disadvantages:
    • Slower cutting speed compared to some other methods.
    • Higher operating costs due to abrasive consumption and maintenance.
    • Limited in thickness when compared to oxy-fuel cutting for certain metals.

Safety Considerations

When it comes to dealing with materials that resist the power of a plasma cutter, safety should always be your top priority. Working with challenging materials presents unique risks that require careful attention.

Safety ConsiderationSafety Tips and Precautions
Personal Protective EquipmentAlways wear appropriate PPE, including safety glasses, welding helmet with a protective lens, flame-resistant clothing, gloves, and steel-toed boots. Ensure that your clothing is free of flammable materials.
VentilationEnsure adequate ventilation in your workspace to disperse fumes and gases generated during cutting. Use a fume extraction system when necessary to prevent inhalation of harmful substances.
Fire SafetyHave fire extinguishers, spark-resistant barriers, and a clear evacuation plan in place. Keep a watchful eye on the surroundings to prevent fires caused by sparks or hot metal.
Material InspectionInspect the material you plan to cut for any foreign objects, contaminants, or hidden hazards. Remove any potential obstructions or hazards from the work area.
Machine MaintenanceRegularly inspect and maintain your cutting equipment. Ensure that hoses, cables, and fittings are in good condition. Follow manufacturer recommendations for maintenance.
GroundingProperly ground your equipment to minimize the risk of electrical shock and arc flash. Check grounding connections regularly to ensure they are secure.
Eye ProtectionUse welding curtains or screens to protect bystanders from the intense light generated during cutting. Make sure that the work area is clearly marked to prevent unauthorized access.
Handling Hazardous MaterialsIf you’re working with materials that may produce toxic fumes or dust when cut, wear appropriate respiratory protection. Be aware of the specific hazards associated with the materials you’re working with.
Emergency ResponseHave a well-equipped first aid kit on hand and know how to use it. Ensure that there is a clear communication method for emergencies, and that all workers are trained in first aid and emergency response procedures.
Training and KnowledgeNever attempt to cut challenging materials without proper training and experience. Seek guidance from experienced professionals or undergo training programs specific to the materials you’ll be working with.


While plasma cutters are versatile and efficient tools for slicing through a variety of metals, they do have their limitations.

Materials like very thick metals, highly reflective metals such as aluminum, and non-conductive substances like wood and plastic are beyond the capabilities of a standard plasma cutter.

It’s important to recognize these limitations for safe operation and optimal results.

When you encounter materials that a plasma cutter can’t handle, consider alternative cutting methods such as laser cutting, waterjet cutting, or traditional mechanical methods.

By understanding the strengths and limitations of your plasma cutter, you can ensure that you choose the right tool for the job every time, maintaining safety, efficiency, and quality in your work.

Frequently Asked Questions

Can I cut stainless steel with a plasma cutter?

Yes, plasma cutters are well-suited for cutting stainless steel. They provide precise and clean cuts on this material.

What materials are challenging for plasma cutting?

Materials like refractory metals (e.g., tungsten, molybdenum), high-reflectivity metals (e.g., copper, aluminum), and non-conductive materials (e.g., wood, plastic) can be challenging for plasma cutting.

How do I choose between alternative cutting methods?

The choice depends on the specific material, thickness, and project requirements. Consider factors such as precision, cutting speed, and heat impact when selecting the most suitable method.

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