Hypertherm Manual Family Operator Manual (OM)

Duramax® Machine Torch Cut Charts for the

®

Powermax45

Cut Charts Guide

810050
Revision 0
January 2018

Hypertherm Inc.

Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[e-mail] (Main Office Email)

800-643-9878 Tel (Technical Service)

[e-mail] (Technical Service Email)

800-737-2978 Tel (Customer Service)

[e-mail] (Customer Service Email)

866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)

[e-mail] (RMA email)

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
[e-mail] (Technical Service Email)

Hypertherm Plasmatechnik GmbH

Sophie-Scholl-Platz 5
63452 Hanau
Germany
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax

31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)

[e-mail] (Technical Service Email)

Hypertherm (Singapore) Pte Ltd.

82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[e-mail] (Marketing Email)
[e-mail] (Technical Service Email)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
[e-mail] (Main Office Email)
[e-mail] (Technical Service Email)

Hypertherm Europe B.V.

Vaartveld 9, 4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)

31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)

[e-mail]
(Technical Service Email)

Hypertherm (Shanghai) Trading Co., Ltd.

B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
86-21-80231120 Fax

86-21-80231128 Tel (Technical Service)

[e-mail]
(Technical Service Email)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
[e-mail] (Technical Service Email)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
[e-mail] (Marketing Email)
[e-mail]
(Technical Service Email)

Hypertherm Pty Limited

GPO Box 4836
Sydney NSW 2001, Australia
61 (0) 437 606 995 Tel
61 7 3219 9010 Fax
[e-mail] (Main Office Email)
[e-mail]
(Technical Service Email)

Hypertherm (India) Thermal Cutting Pvt. Ltd

A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[e-mail] (Main Office Email)
[e-mail]
(Technical Service Email)

1/28/16

© 2018 Hypertherm Inc. All rights reserved.
Powermax, Duramax, FineCut, and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and/or other countries. All other trademarks are

the property of their respective holders.
Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We are striving to reduce the environmental

impact of everything we do. For more information:www.hypertherm.com/environment.

Using the cut charts

Use the cut charts in this document:

 Only for Duramax

 As a starting point

Adjust the variables in the cut charts as needed to achieve optimal results for your cutting
equipment and environment.

The cut charts are based on the latest process development from the



Powermax45 XP and provide a wider range of material thicknesses than
previous 45 A cut charts for Duramax torches.

If you are using a T45m torch with the Powermax45, use the cut charts in



the Powermax45 Operator Manual (805780). For Powermax45 XP cut
charts, refer to the Powermax45 XP Operator Manual (809240).
Download the manuals at www.hypertherm.com/docs

Duramax Machine Torch Cut Charts for the Powermax45

®

machine torches on the Powermax45

.

Cut charts are provided for each set of mechanized cutting consumables. A consumable diagram
with part numbers precedes each cut chart.

Cut charts are included for:

 Cutting mild steel, stainless steel, and aluminum at 45 A with air using shielded

consumables

 Cutting mild steel and stainless steel with air using FineCut consumables

 Cutting stainless steel at 45 A with F5 gas using shielded consumables

Each cut chart may contain the following information:

 Amperage setting – The amperage setting at the top of the page applies to all the settings

given on that page. In FineCut

®

charts, the amperage setting for each thickness is included

in the cut chart.

 Material Thickness – Thickness of the workpiece (metal plate being cut).

 Torch-to-Work Distance – For shielded consumables, the distance between the shield and

the workpiece during cutting. For unshielded consumables, the distance between the nozzle
and the workpiece during cutting. This is also known as cut height.

 Initial Pierce Height – Distance between the shield (shielded) or the nozzle (unshielded)

and the workpiece when the torch is fired, prior to descending to the cut height.

 Pierce Delay Time – Length of time the triggered torch remains stationary at the pierce

height before the torch starts the cutting motion.

 Best Quality Settings (cut speed and voltage) – Settings that provide the starting point for

finding the best cut quality (best angle, least dross, best cut-surface finish). Adjust the
speed for your application and table to obtain the desired result.

Powermax45 Cut Charts Guide 810050 3

Duramax Machine Torch Cut Charts for the Powermax45

 Production Settings (cut speed and voltage) – 70% to 80% of the maximum speed

ratings. These speeds result in the greatest number of cut parts, but not necessarily the best
possible cut quality.

The arc voltage increases as the consumables wear, so the voltage



setting may need to be increased to maintain the correct torch-to-work
distance. Some CNCs monitor the arc voltage and adjust the torch lifter
automatically.

 Kerf Width – Width of material removed by the cutting process. The kerf widths were

obtained with the “Best Quality” settings and are for reference only. Differences between
installations and material composition may cause actual results to vary from those shown.

Each cut chart lists hot and cold gas flow rates.

 Hot flow rate – Plasma is on, the system is operating at running current, and the system is

in a steady state at the default system pressure (cutflow, or automatic mode).

 Cold flow rate – Plasma is off and the system is in a steady state with gas flowing through

the torch at the default system pressure (postflow).

Hypertherm collected the cut chart data under laboratory test conditions



using new consumables.

WAR NING

EXPLOSION HAZARD – CUTTING WITH ALUMINUM NEAR WATER

Do not cut aluminum alloys underwater or on a water table unless you can prevent the accumulation
of hydrogen gas. Never cut aluminum-lithium alloys in the presence of water.

Aluminum can react with water to produce hydrogen, resulting in a potentially explosive condition
that can detonate during plasma cutting operations. Refer to the Safety and Compliance Manual
(80669C) for more information.

WAR NING

TOXIC FUMES CAN CAUSE INJURY OR DEATH

Some metals, including stainless steel, may release toxic fumes when cut. Make sure your work site
has adequate ventilation to ensure that the air quality level meets all local and national standards
and regulations. Refer to the Safety and Compliance Manual (80669C) for more information.

WAR NING

EXPLOSION HAZARD – CUTTING WITH FUEL GASES

Do not use combustible fuel gases or oxidizing gases with Powermax systems. These gases can
result in explosive conditions during plasma cutting operations.

4 810050 Cut Charts Guide Powermax45

Duramax Machine Torch Cut Charts for the Powermax45

WAR NING

GAS CYLINDERS CAN EXPLODE IF DAMAGED

Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. For high
pressure regulators, adhere to the manufacturer’s guidelines for safe installation, operation, and
maintenance.

Before plasma cutting with compressed gas, read the safety instructions in the Safety and
Compliance Manual (80669C). Failure to follow safety instructions can result in personal injury or
in damage to equipment.

Powermax45 Cut Charts Guide 810050 5

Duramax Machine Torch Cut Charts for the Powermax45

220817 220854

(220953 for

ohmic sensing)

220941 220857220842

Mild Steel – 45 A – Air – Shielded

Metric

Material

Thickness

mm mm mm % seconds mm/min volts mm/min volts mm

2
3 3960 128 5590 128

To rc h- to - Wo rk

Distance

Initial Pierce Height

Pierce

Delay Time

0.2

4 0.4 2800 128 3960 128
6
8 1020 133 1385 130 1.7

1.5 3.8 250

0.6

10 0.8 780 136 920 134 1.8
12 1 540 140 690 138 1.9
16
20 170 152 240 147 2.3

Edge Start

25 110 157 145 154 3

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

5560 128 7910 125

1430 130 2110 127

310 146 400 141 2.1

Kerf Width

1.4

1.5

English

Material

Thickness

inches inches inches % seconds in/min volts in/min volts inches

16 GA

To rc h- to - Wo rk

Distance

Initial Pierce Height

Pierce

Delay Time

0.1 249 128 320 125 0.053
14 GA 0.2 225 128 320 125 0.054
10 GA 0.4 129 128 181 128 0.057

3/16 0.5 85 129 122 127 0.059

0.06 0.15 250
1/4 0.6 48 130 72 127 0.061
3/8 0.8 33 136 38 133 0.069
1/2 1 18 141 24 139 0.077
5/8
3/4 7 151 10 145 0.086
7/8 6 154 7 151 0.103

Edge Start

1 4 157 6 154 0.119

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

13 146 16 141 0.082

Gas flow rate – slpm / scfh

151 / 320 Hot (cutflow)
184 / 390 Cold (postflow)

Kerf Width

6 810050 Cut Charts Guide Powermax45

Duramax Machine Torch Cut Charts for the Powermax45

220817 220854

(220953 for

ohmic sensing)

220941 220857220842

Stainless Steel – 45 A – Air – Shielded

Metric

Material

Thickness

mm mm mm % seconds mm/min volts mm/min volts mm

2

To rc h- to - Wo rk

Distance

Initial Pierce Height

Pierce

Delay Time

0.1 5620 126 7830 129 0.6
3 0.2 3285 129 4725 128 0.9
4 0.4 1995 130 2960 129 1.1
6
8 830 1341100134 1.4

1.5

3.8 250

0.6

10 0.8 605 137 870 137 1.6
12 4.6 300 1.2 380 141 540 139 1.8
16
20 160 149 205 146 3.1

Edge Start

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

1145 131 1695 131 1.2

240 145 320 142 2.4

Kerf Width

English

Material

Thickness

inches inches inches % seconds in/min volts in/min volts inches

16 GA

To rc h- to - Wo rk

Distance

Initial Pierce Height

Pierce

Delay Time

0.1 237 125 320 128 0.017

14 GA 0.2 230 126 320 129 0.022
10 GA 0.4 90 130 134 128 0.041

3/16 0.5 63 131 93 130 0.044

1/4 0.6 40 131 59 131 0.047
3/8 0.8 26 137 29 136 0.061

0.06

0.15 250

1/2 0.18 300 1.2 12 142 19 140 0.075
5/8
3/4 7 148 9 145 0.116

Edge Start

7/8 5 151 6 149 0.137

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

10 145 13 142 0.096

Gas flow rate – slpm / scfh

151 / 320 Hot (cutflow)
184 / 390 Cold (postflow)

Kerf Width

Powermax45 Cut Charts Guide 810050 7

Duramax Machine Torch Cut Charts for the Powermax45

220817 220854

(220953 for

ohmic sensing)

220941 220857220842

Aluminum – 45 A – Air – Shielded

Metric

Material

Thickness

mm mm mm % seconds mm/min volts mm/min volts mm

2

To rc h- to - Wo rk

Distance

Initial Pierce Height

Pierce

Delay Time

0.1 7890 121 9585 134 1.3
3 0.2 4850 130 7120 129
4 0.4 3670 133 5650 129
6 0.5 2060 139 3095 132 1.6
8 0.6 1330 139 1830 136 1.7

1.5

3.8 250

10 0.7 860 142 1015 140 1.9
12
16 360 152 340 148 2.5

Edge Start

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

620 144 745 142 2

Kerf Width

1.5

English

Material

Thickness

inches inches inches % seconds in/min volts in/min volts inches

1/10

1/8

3/16 120 134 184 130 0.061

1/4 0.5 70 137 104 132 0.063
3/8 0.7 36 141 42 139 0.073

To rc h- to - Wo rk

Distance

0.06

Initial Pierce Height

0.15 250

Pierce

Delay Time

0.2 240 126 320 131 0.056

0.4

1/2
5/8 15 152 14 148 0.100

Edge Start

3/4 8 158 9 153 0.117

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

170 131 263 128 0.060

21 145 26 143 0.082

Gas flow rate – slpm / scfh

151 / 320 Hot (cutflow)
184 / 390 Cold (postflow)

Kerf Width

8 810050 Cut Charts Guide Powermax45

Duramax Machine Torch Cut Charts for the Powermax45

220955 (deflector)

220948 (shield)

220854

220953 (ohmic)

220930 220947220842

Mild Steel – FineCut – Air – Shielded and Unshielded

Metric

Material Thickness Current

mm A mm mm % seconds mm/min volts mm

0.5

0.6 8250 78

40

To rc h- to - Wo rk

Distance

Initial Pierce Height Pierce Delay Time

0.0

0.8 0.1 8250 78 0.6
1

1.5
2 4800 78

45

1.5 3.8 250

0.2 8250 78 0.7

0.4

4 0.6 1900 78

Recommended

Cut Speed Voltage

8250 78

6400 78 1.2

Kerf Width

0.7

1.33 0.5 2500 78

English

Material Thickness Current

inches A inches inches % seconds in/min volts inches

26 GA
24 GA 325 78 0.029
22 GA

40

20 GA 325 78 0.020
18 GA
16 GA
14 GA 200 78 0.049

45
12 GA
10 GA 95 78 0.051

To rc h- to - Wo rk

Distance

Initial Pierce Height Pierce Delay Time

0.06 0.15 250

0.0

0.1

0.2 325 78 0.043

0.4

0.5

Best Quality Settings

Cut Speed Voltage

325 78 0.025

325 78 0.024

250 78 0.046

120 78 0.052

Gas flow rate – slpm / scfh

155 / 330 Hot (cutflow)
215 / 460 Cold (postflow)

Kerf Width

Powermax45 Cut Charts Guide 810050 9

Duramax Machine Torch Cut Charts for the Powermax45

220955 (deflector)

220948 (shield)

220854

220953 (ohmic)

220930 220947220842

Stainless Steel – FineCut – Air – Shielded and Unshielded

Metric

Material Thickness Current

mm A mm mm % seconds mm/min volts mm

0.5

0.6 8250 68

40

To rc h- to - Wo rk

Distance

Initial Pierce Height Pierce Delay Time

0.0

0.8 0.1 8250 68
1

1.5
2 4800 71

45

0.5 2.0 400

0.2 8250 68 0.6

0.4

3 0.5 2550 80 1.4

40.61050841.5

Recommended

Cut Speed Voltage

8250 68 0.6

6150 70

Kerf Width

0.5

1.0

English

Material Thickness Current

inches A inches inches % seconds in/min volts inches

26 GA
24 GA 325 68 0.021
22 GA

40

20 GA 325 68 0.017
18 GA
16 GA
14 GA 200 70 0.040

45

To rc h- to - Wo rk

Distance

Initial Pierce Height Pierce Delay Time

0.02 0.08 400

0.0

0.1

0.2 325 68 0.036

0.4

12 GA 0.5 120 80 0.049
10 GA 0.6 75 80 0.055

Best Quality Settings

Cut Speed Voltage

325 68 0.024

325 68 0.018

240 70 0.039

Gas flow rate – slpm / scfh

155 / 330 Hot (cutflow)
215 / 460 Cold (postflow)

Kerf Width

10 810050 Cut Charts Guide Powermax45

Duramax Machine Torch Cut Charts for the Powermax45

220955 (deflector)

220948 (shield)

220854

220953 (ohmic)

220930 220947220842

Mild Steel – FineCut Low Speed – Air – Shielded and Unshielded

Metric

Material Thickness Current

mm A mm mm % seconds mm/min volts mm

0.5

30

To rc h- to - Wo rk

Distance

Initial Pierce Height Pierce Delay Time

0.0

0.8 0.1 3800 70

1*

1.5*

40

1.5 3.8 250

2

30.52750781.3

45

0.2 3800 72

0.4

4 0.6 1900 78 1.5

Recommended

Cut Speed Voltage

Kerf Width

3800 69

3800 75
3700 76 0.7

0.60.6 3800 68

0.8

English

Material Thickness Current

inches A inches inches % seconds in/min volts inches

26 GA
24 GA 150 68 0.024
22 GA

30

20 GA 150 71
18 GA

16 GA*

40

14 GA*

12 GA

45

10 GA 95 78 0.051

To rc h- to - Wo rk

Distance

Initial Pierce Height Pierce Delay Time

0.06 0.15 250

0.0

0.1

0.2 150 73 0.031

0.4

0.5

Best Quality Settings

Cut Speed Voltage

150 70 0.026

150 70

150 75 0.029
150 76 0.027
120 78 0.052

Gas flow rate – slpm / scfh

155 / 330 Hot (cutflow)
215 / 460 Cold (postflow)

* Not a dross-free cut.

Kerf Width

0.025

Powermax45 Cut Charts Guide 810050 11

Duramax Machine Torch Cut Charts for the Powermax45

220955 (deflector)

220948 (shield)

220854

220953 (ohmic)

220930 220947220842

Stainless Steel – FineCut Low Speed – Air – Shielded and Unshielded

Metric

Material Thickness Current

mm A mm mm % seconds mm/min volts mm

0.5

30

To rc h- to - Wo rk

Distance

Initial Pierce Height Pierce Delay Time

0.0

0.8 0.1 3800 69
1

1.5

40

0.5 2.0 400

2 2750 69 1.3
3

40.61050801.5

45

0.2 3800 69 0.6

0.4

0.5 2550 80 1.4

Recommended

Cut Speed Voltage

3800 69

2900 69 0.5

Kerf Width

0.70.6 3800 69

English

Material Thickness Current

inches A inches inches % seconds in/min volts inches

26 GA
24 GA 150 69
22 GA

30

20 GA 150 69
18 GA
16 GA

40
14 GA 110 69 0.021
12 GA
10 GA 0.6 75 80 0.055

45

To rc h- to - Wo rk

Distance

Initial Pierce Height Pierce Delay Time

0.02 0.08 400

0.0

0.1

0.2 145 69

0.4

0.5 120 80 0.049

Best Quality Settings

Cut Speed Voltage

150 69

150 69 0.025

115 69 0.022

Gas flow rate – slpm / scfh

155 / 330 Hot (cutflow)
215 / 460 Cold (postflow)

Kerf Width

0.028

0.023

12 810050 Cut Charts Guide Powermax45

Duramax Machine Torch Cut Charts for the Powermax45

220817 220854

(220953 for

ohmic sensing)

220941 220857220842

Stainless Steel – 45 A – F5 – Shielded

When used with a Powermax system, F5 should be used only to cut stainless steel.

For more information on cutting with F5, download the Use F5 to Cut



Stainless Steel (809060) Application Note at

www.hypertherm.com/docs

Metric

Material

Thickness

mm mm mm % seconds mm/min volts mm/min volts mm

8
10 435 153 525 147 2.3
12 Edge Start 340 156 440 150 2.5

To rc h- to - Wo rk

Distance

1.5

Initial Pierce Height

3.8 250 0.8

.

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

630 150 860 144 2.1

Kerf Width

English

Material

Thickness

inches inches inches % seconds in/min volts in/min volts inches

1/4
3/8 0.8 18 152 22 146 0.088
1/2 Edge Start 12 157 16 151 0.101

To rc h- to - Wo rk

Distance

0.06

Initial Pierce Height

0.15 250

Pierce

Delay Time

0.6 32 147 47 141 0.075

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

Gas flow rate – slpm / scfh

149 / 315 Hot (cutflow)
184 / 390 Cold (postflow)

F5 is not recommended for thicknesses less than 7 mm or 1/4 inch or for



use with FineCut consumables.

Kerf Width

Powermax45 Cut Charts Guide 810050 13