Easy casting sprue removal leads to reduced grinding operations – Hypertherm’s FlushCut

The new flush cutting process is helpful for a number of applications including jobs that require the separation of two metals. Allows users to cut attachments, lugs, pad eyes and other positive features as close to the base as possible without piercing or damaging the workpiece.

Hypertherm, a manufacturer of plasma, laser, and waterjet cutting systems, has announced the release of FlushCut™ consumables for select Powermax® air plasma systems. The consumables, which are now available for Powermax105 and Powermax125 systems, provide users with the ability to cut closer to base materials than ever before. FlushCut consumables feature an angled nozzle bore that delivers the plasma arc at a 45-degree angle ideal for challenging removal applications. Instead of locating the nozzle opening at the tip as is typically done, the nozzle orifice is located on the side. This essentially bends the plasma arc, causing it to exit the torch at an angle nearly parallel to the workpiece. As a result, users can cut closer, or more flush, to the base metal than ever before, significantly reducing grinding work and increasing the opportunity to reuse lugs and attachments.

Traditionally, lug and attachment removal has relied on carbon arc gouging, oxyfuel and traditional plasma cutting equipment. However, these applications can be inefficient, time consuming and may pierce or damage the actual work piece.

In comparison to oxyfuel applications, FlushCut plasma cutting requires much less pre-processing time and reduces heat-affected zones up to 10x less. With carbon arc gouging, multiple passes are needed to accomplish the same as a FlushCut plasma process can do in a single pass, not to mention the increased smoke and noise. While traditional plasma cutters only allow the user to cut at a steep angle, creating more need for secondary repairs, such as grinding.

An angled nozzle bore design and flat guiding shield enables flush cutting that leaves less than 5mm residual material on the base or work piece, reducing grinding and secondary repair operations.

Typical flush cutting applications include removing lugs, pad eyes and temporary weld supports, material washing, end cap removal, rat hole cuts in I and H beams, bolt and rivet washing, casting sprue removal, post tension cable tail cuts and wearable part removal/replacement.

FlushCut consumables can be used in handheld applications. This new process has the potential to save companies a substantial amount of time while reducing operator fatigue and increasing safety on the jobsite.

The introduction of FlushCut consumables is just one more example of how Hypertherm is helping customers address challenging metal cutting and removal applications. The company’s engineers have developed numerous torch and specialty consumable options including consumables for gouging, extended reach cutting, marking, and fine feature cutting.

A testimonial video has also been made by Hypertherm. The video can be viewed at https://www.hypertherm.com/learn/case-studies/34

For more information contact Craig Sterly of Hypertherm on email craig.sterly@hypertherm.com or visit www.hypertherm.com