Plasma cutting is a melting process in which a jet of ionised gas at temperatures above 20,000°C is used to melt and expel material from the cut. During the process, an electric arc is struck between an electrode (cathode) and the workpiece (anode). The electrode is recessed in a water- or air-cooled gas nozzle which constricts the arc causing the narrow, high temperature, high velocity plasma jet to form.
When the plasma jet hits the workpiece, recombination takes place and the gas reverts to its normal state, emitting intense heat as it does so. This heat melts the metal and the gas flow ejects it from the cut. Plasma gases are usually argon, argon/hydrogen or nitrogen. These inert gases can be replaced by air but this requires a special electrode of hafnium or zirconium. Use of compressed air makes this variant of the plasma process highly competitive with the oxy-fuel process for cutting carbon-manganese and stainless steels up to 20mm thick. Inert gases are preferred for high quality cuts in reactive alloys.