Can plasma cut stainless steel?

Yes, plasma can effectively cut stainless steel. Plasma cutting is a process that uses ionized gas at high temperatures to melt and remove metal, making it suitable for stainless steel and other metals. The high-temperature plasma arc provides precise and fast cutting, making it a popular choice in various industries for cutting stainless steel sheets, pipes, and other components with accuracy and efficiency.

Can plasma cut stainless steel

Introduction to Plasma Cutting

What is Plasma Cutting?

Plasma cutting is a process that utilizes a high-speed jet of ionized gas, or plasma, to heat and cut through different types of electrically conductive materials. Materials suitable for plasma cutting include steel, stainless steel, aluminum, brass, and copper.

History of Plasma Cutting

Plasma cutting was initially developed as part of the plasma welding process in the mid-20th century. The early plasma cutters were large, slow, and expensive, but they’ve evolved significantly since then. By the 1980s, plasma cutting technology had become smaller, faster, and more affordable, allowing for broader use across various industries.

Plasma Cutting Process Overview

The plasma cutting process starts by creating an electrical channel of superheated, electrically ionized gas from the cutter itself through the work piece to be cut. The electrical arc formed within the device, through the inert gas, becomes so hot (reaching up to 30,000 Fahrenheit or 16,649 Celsius) that it turns into plasma. This high-speed plasma jet melts the metal, and the molten metal is then blown away, forming a cut.

Components of a Plasma Cutter

A typical plasma cutter consists of a power supply, an arc starting circuit, and a torch. The power supply regulates voltage and current, typically ranging between 15 and 200 amps. The arc circuit provides the initial spark, and the torch conducts the plasma and focuses it onto the material.

Advantages of Plasma Cutting

Plasma cutting offers several advantages over other types of cutting methods, such as oxy-fuel cutting or mechanical cutting.

High Speed and Precision

Plasma cutting is known for its speed and precision. It can reach cutting speeds up to five times faster than traditional torch cutting methods, making it a preferred method for many industrial applications. This speed does not sacrifice accuracy; plasma cutters can achieve a cut accuracy within 0.01 inches (0.25 mm).


Plasma cutting is versatile and can be used with any type of conductive material. This includes not only various metals, but also metal thicknesses. A handheld plasma system can typically cut steel up to 1.5 inches (38 mm) thick, while a more powerful, industrial computer numerical control (CNC) machine can cut steel up to 6 inches (152 mm) thick.

Low Operational Cost

The operational cost of plasma cutting is relatively low compared to other methods. For example, a typical plasma cutting machine may cost around $1,500, with operational costs amounting to roughly $25 per hour.

Stainless Steel Cutting

Plasma Cutting Equipment for Stainless Steel

The primary components of these systems include the power source, plasma torch, ground clamp, air compressor, and consumables. Each of these components plays a vital role in ensuring the accuracy and quality of the cut.

Power Source

The power source supplies the energy required for the cutting process. Depending on the specific model, it can deliver power ranging from 10 to over 100 amps. For example, the Hypertherm Powermax45 XP is a popular choice with a cutting power of 45 amps. This model typically costs around $2,000.

Plasma Torch

Some torches also include a “pilot arc” between the electrode and the nozzle to initiate the plasma arc.

Ground Clamp

The ground clamp is a critical safety feature that prevents electrical shock by ensuring the current has a path to the ground. Its size and build depend on the specific model of the plasma cutter.

Air Compressor

The air compressor supplies the pressurized gas that becomes the plasma. The required pressure can vary depending on the thickness of the material being cut but typically ranges between 60 and 80 PSI.


They include electrodes, nozzles, and shields. The cost of consumables varies, but on average, you can expect to spend around $100 to $200 per year, depending on the frequency of use.

Selecting the Right Plasma Cutter for Stainless Steel

Choosing the right plasma cutter for stainless steel involves considering a few key factors: the thickness of the material, the precision required, the working environment, and of course, the budget.

Material Thickness

Different plasma cutters are designed to handle different material thicknesses. For instance, a unit like the Miller Spectrum 375 X-TREME can cut stainless steel up to 3/8″ thick, while larger units can handle up to 2″ thickness.

Precision Requirements

The precision of the plasma cutter is another crucial factor. Some models provide a finer cut, ideal for detailed work or welding preparation, while others are designed for rougher, quick cuts.

Working Environment

If you are working in a small, enclosed space, a more compact unit like the Hobart Airforce 12ci with built-in air compressor might be preferable. In contrast, larger, industrial-scale projects might require a heftier model like the Hypertherm Powermax 105.


The cost of plasma cutters can range widely, from $500 for entry-level models to over $10,000 for high-end industrial models. Therefore, it’s essential to consider your budget alongside your cutting needs.


Plasma Gas Selection for Stainless Steel Cutting

Gas Types

The most commonly used gases in plasma cutting are air, nitrogen, oxygen, and argon-hydrogen mixtures.

  • Air is the most economical option and can produce excellent quality cuts on stainless steel. However, it might lead to faster consumable wear. The typical cost of compressed air is around $0.25 to $0.35 per 1,000 cubic feet.
  • Nitrogen is often used for higher current plasma systems and can provide excellent high-speed cutting on stainless steel. Nitrogen usually costs around $0.50 to $1.00 per 1,000 cubic feet.
  • Oxygen is used for cutting mild steel as it provides a very clean, high-quality cut.
  • Argon-Hydrogen Mixtures are primarily used for cutting thicker stainless steel. They can provide a very smooth cut edge with minimal dross. These gases are typically the most expensive, costing approximately $1.50 to $2.00 per 1,000 cubic feet.

Comparison of Different Plasma Gases for Stainless Steel

When cutting stainless steel, it’s crucial to consider the benefits and drawbacks of the various plasma gases available.


The main advantage of using air as your plasma gas is its low cost and availability. However, using air can lead to a phenomenon called “nitriding,” which can make the cut surface harder and more difficult to machine.


Nitrogen can produce a very clean cut on stainless steel, especially at high cutting speeds. But it can cause high-frequency arc starting issues which might affect the cut quality and consumable life.


Oxygen isn’t typically used for cutting stainless steel due to the potential for oxidation that can degrade the cut quality.

Argon-Hydrogen Mixtures

Argon-Hydrogen mixtures provide an excellent cut quality, especially for thicker materials. They also result in longer consumable life.

Comparing Plasma Cutting with Other Cutting Techniques for Stainless Steel

Plasma Cutting

Plasma cutting excels when it comes to cutting thicker materials. It’s faster and more cost-effective for cutting materials over 3mm thick. The typical cost per hour of operation for a plasma cutter is about $25-$35.


  • Faster cutting speeds on thicker materials
  • Lower initial equipment cost compared to laser cutters
  • The ability to cut conductive material

Laser Cutting

Laser cutting, particularly fiber laser, excels at cutting thin to medium thickness materials with high precision. However, the cost per hour of operation is higher, often around $20-$40 for the laser gas and $15-$20 for electricity.


  • Superior precision and edge quality
  • Smaller heat-affected zone
  • Capable of cutting non-conductive materials

Plasma Cutting

Fast, precise, versatile cutting of various materials. Minimal warping, cost-effective, clean cuts. Suitable for thick metals, easy automation, and CNC integration. Portable, requires less operator skill. Popular in construction, automotive, aerospace, and manufacturing industries.


Waterjet Cutting

Waterjet cutting is a non-thermal process that uses a high-pressure stream of water, often mixed with abrasive materials, to cut through materials. This method is particularly suitable for cutting materials sensitive to high temperatures. However, its operational costs can be high, often ranging from $20 to $40 per hour, mainly due to the cost of abrasive materials.


  • No heat-affected zone, eliminating the risk of material warping or distortion
  • Capable of cutting a wider variety of materials, including non-metallic and heat-sensitive materials
  • Can handle thicker materials

What is plasma cutting?

Plasma cutting is a thermal cutting process that utilizes ionized gas to melt and expel metal, enabling efficient cutting of various materials, including stainless steel.

Can plasma cutting be used for other metals besides stainless steel?

Yes, plasma cutting is versatile and can be used for cutting other metals like carbon steel, aluminum, copper, and more.

What are the advantages of plasma cutting stainless steel?

Plasma cutting provides high cutting speed, precision, and the ability to cut through thicker stainless steel materials compared to other cutting methods.

Is plasma cutting safe for stainless steel?

Yes, when conducted by trained professionals and using proper safety measures, plasma cutting is a safe method for cutting stainless steel.

What industries commonly use plasma cutting for stainless steel?

Industries such as manufacturing, construction, automotive, and aerospace frequently employ plasma cutting for stainless steel fabrication.

What thickness of stainless steel can be cut with plasma?

Plasma cutting can efficiently cut stainless steel ranging from thin sheets to several inches in thickness.

Does plasma cutting generate any hazardous fumes when cutting stainless steel?

Yes, plasma cutting may produce fumes and gases, including those from the stainless steel material, which require proper ventilation and respiratory protection.

Can plasma cutting result in a smooth finish on stainless steel?

While plasma cutting provides precise and fast cutting, the finish may not always be as smooth as other cutting methods. Additional post-cutting processes may be needed for a smoother surface.

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