For increased productivity when performing automated plasma cutting, ESAB has launched enhanced versions of its 200, 300 and 400 A iSeries high-precision plasma power sources to double cutting output to 400, 600 or 800 A, respectively. This new capability, standard on iSeries systems manufactured after 1 March, requires using matching consumables, a connection kit with cabling and associated software for the controller.

“The concept is similar to paralleling two welding power sources to use larger diameter electrodes for increased productivity,” explains Dirk Ott, VP – global plasma automation. “This new capability features some modest software and hardware enhancements, but the challenge was developing the new 600 and 800 A consumables for stainless steel and aluminium.

Ott notes that consumables are the most highly engineered components in an automated plasma cutting system, and that achieving optimal cut quality and speed requires changing consumables to match the application. ESAB now offers consumables for automated plasma cutting outputs from 15 to 800 A.

Target applications include fabricators and steel service centres that use two torches on the same gantry, and those cutting sections of stainless steel and aluminium material up to 160 mm, which are primarily in the power generation, pressure vessel, chemical and petrochemical processing industries.

Users of 600 and 800 A systems mostly want faster cutting speeds on non-ferrous material that ranges from 50 to 100 mm. As an example, the 600 A system cuts 75 mm stainless steel at 330 mm/min using H35 (the H35 process uses 35% hydrogen/65% nitrogen for the plasma gas and nitrogen for the shielding gas).

For further information
www.esab.co.uk

With the ConSus abrasive mixing unit, waterjet cutting specialist ConSus ANT is enabling the stationary use of water abrasive suspension (WAS) systems. A continuous suspension jet provides a more efficient cutting performance at lower pressure compared with conventional water abrasive injection systems (WAIS). For easy, customisable performance comparison of both methods, a free web app is available.

In many industries, R&D teams regularly develop new materials for which suitable machining processes must be found. For a large number of materials, waterjet cutting with WAS proves to be technically superior and economically more profitable than conventional cutting techniques. Compared with WAIS, the ConSus suspension jet operates at less than half the pressure and up to three times as fast. The user receives thin kerfs without hardening or material deformation. ConSus demonstrates its strengths particularly at increased cutting depths.

In contrast to three-phase WAIS systems with water, abrasive and air, the ConSus WAS system operates with a two-phase cutting jet of water and abrasive at a precisely adjustable flow rate. ConSus applies high pressure to the suspension before it reaches the remotely handled cutting nozzle. The high level of energy creates a cutting jet that emerges at almost twice the speed of sound. Its efficiency is much higher than that of the injection process, where turbulent mixing losses occur due to the contained air. The more focused WAS jet cuts precisely through even the hardest materials. That way, it is possible to cut material with a thickness of up to 1000 mm, while still maintaining very good surface structure.

ConSus operates at a maximum pressure of 1500 bar, even at enormous material thicknesses, which significantly reduces energy consumption and component wear.

For further information
https://waterjet-calculator.consus-gmbh.com

The precise processing of exceptionally large or thick plates is a job for specialists such as Otto Klostermann GmbH. Klostermann has many years’ experience and comprehensive know-how in processing large plates with its range of XXL-format machines. When it comes to thermal cutting – no matter whether oxy-fuel, plasma or laser – this plate processing specialist from Castrop-Rauxel uses modern, high-performance machines from Messer Cutting Systems.

With its newest investment, a LaserMat II, Klostermann now relies for laser cutting on the problem-solving skills of Messer Cutting Systems.

“Our old laser cutting system was getting on in years,” says managing director Philipp Klostermann. “It was no longer state-of-the-art and spare parts were unavailable. As the machine was totally loaded all year round, it was clear that we needed a new one. We are very satisfied with our existing OmniMat plasma and oxy-fuel cutting systems. They work flawlessly every day and have never let us down. An additional benefit is their size: we mainly process very large plates, and the Messer machines can process these XXL sizes. So, for us, only a laser system from Messer came into consideration.”

With the LaserMat II, the steel specialist found the perfect cutting system. The machine was conceived specially for large plate processing with its CO2 laser, and combines precision with speed – even when processing steel sheets weighing many tonnes.

With its new laser system, Klostermann can, for example, cut mild steel up to 25 mm thick, or stainless steel up to 20 mm thick. Thanks to the on-board laser beam source (resonator), it is possible to process plates up to 4500 mm wide and up to 30 m long.

For further information
https://uk.messer-cutting.com/