To plasma cut aluminum, install the consumables your chart lists, connect clean dry air, set the amperage for your thickness, hold a steady torch height and move at a speed that sends sparks straight down through the cut. Check the cut chart in your manual first, and make a test cut on scrap from the same sheet.
Quick Answer
Yes, a plasma cutter cuts aluminum. There is no universal amperage or speed, so follow your machine’s chart. Portable air-plasma cutters use clean, dry air. Wear proper eye protection, control the fumes and never cut aluminum over water unless the table is built for it.
How to Plasma Cut Aluminum Step by Step
- Read the aluminum chart. Find the amperage, consumables, air pressure and cut height your manual lists for your thickness.
- Fit the right consumables. Install the nozzle, electrode and shield for that amperage, and replace any that look worn.
- Prepare the air. Drain the compressor and filter so the air is clean and dry.
- Clean the metal. Remove paint, oil, adhesive film and dirt from the cut line and from the clamp spot.
- Attach the work clamp to clean bare metal close to the cut.
- Set the current and pressure from the chart.
- Make a test cut on scrap of the same thickness. Watch the sparks and check the bottom edge.
- Adjust one thing at a time. Change speed first, then height, then current, and re-test.
What You Need Before You Start
| Item | Why you need it |
|---|---|
| Plasma cutter rated for your aluminum thickness | Check the quality-cut rating, not only the maximum severance number |
| Matching consumables | Nozzle, electrode and shield must match the amperage on the chart |
| Clean, dry air supply | Moisture and oil weaken the arc and wear consumables faster |
| Work clamp and clean metal | A weak ground causes hard starts and arc drops |
| Straightedge or guide | Keeps hand cuts straight and the standoff steady |
| Scrap aluminum | For test cuts before the finished part |
| PPE and ventilation | Eye protection, gloves, flame-resistant clothing and fume control |
Products Worth Considering
【Precise 50-60 PSI Working Pressure】Professionally calibrated for 50-60 PSI optimal working air pressure, the machine maintains consistent plasma arc stability during long-hour cutting. Standard air pressure setting effectively reduces slag adhesion, avoids uneven cutting and arc breaking issues, and ensures smooth, neat cutting edges for all applicable metal materials.
PLEASE NOTE: Gas MIG, Flux Core MIG, and Aluminum Welding all require the spool gun to operate. Spool gun and Lift TIG torch are not included and need to be purchased separately.
VERSTILE CUTTING & SURFACE TREATMENT: This all-in-one tool supports cutting, rust removal, gouging and marking. It enables continuous cutting on mesh materials, non-contact cleaning, surface finishing and paint stripping for fabrication and repair work. Supports 2T (short cuts) & 4T (long cuts) modes (Recommended for use 50A+ breaker for 120V, and 30A+ breaker for 240V)
Settings for Plasma Cutting Aluminum
Settings come as a set, so copy them from one chart rather than mixing numbers from different sources. As a reference point, a Hypertherm Powermax45 mechanized air chart lists 45 amps for 1/8 inch aluminum, with 170 IPM for best quality and 0.06 inch cut height. A handheld cutter from another brand can use different values.
Thicker aluminum needs more current and slower travel. If your machine is near its rated thickness, start the cut from the edge instead of piercing. For a full thickness walkthrough, see our guides to plasma cutting 1/8 inch aluminum and plasma cutter settings for aluminum.
Products Worth Considering
【Powerful Cutting Ability】Switch effortlessly between 110V and 220V for home or workshop use. Achieve professional 1/2" clean cuts on steel, aluminum, and copper with advanced LGBT technology. Perfect for DIY projects and heavy-duty tasks. Recommended maximum cutting thickness: 12mm @ 35A / 110V / 55 PSl; 18mm @ 50A / 220V / 75 PSI. Note: Requires compressed air (compressor sold separately).
Includes 10pcs 56576 Electrode + 10pcs 56811 Tip / Nozzle
Package Including: The package contains 2 pieces of plasma double pointed spacer 60432
Choose the Right Gas
On a typical portable plasma cutter, use clean, dry air. It cuts aluminum, but the edge is more oxidized and should be ground to bright metal before welding. Multi-gas industrial systems may use nitrogen, nitrogen with a water shield, or a hydrogen mix for thick plate, according to Hypertherm’s aluminum guide. Only use gases your cutter’s manual approves.
Fix Common Beginner Mistakes
| Mistake | What you see | Fix |
|---|---|---|
| Moving too fast | Sparks trail behind or spray back, cut does not separate | Slow down until sparks go straight down |
| Moving too slow | Wide kerf, heavy bottom dross, warped sheet | Speed up in small steps |
| Torch height uneven | Bevel and rough edge | Hold a steady standoff or use a guide |
| Wet or oily air | Sputtering arc, short consumable life | Drain the tank and add a filter |
| Poor ground | Arc will not start or drops out | Move the clamp to clean bare metal |
| Worn consumables | Rough edge, wandering arc | Replace the nozzle and electrode |
Safety and Fumes When Cutting Aluminum
- Fumes: Cutting releases metal oxide particles, and coatings add more. Use local exhaust or cut outdoors with airflow, and see OSHA’s guidance on welding fumes.
- Eyes and skin: Use the lens shade your cutter’s manual specifies, plus gloves and flame-resistant clothing.
- Fire: Clear combustibles and let hot offcuts cool in a safe place.
- Water tables: Aluminum cut over water can produce hydrogen. Do not use a water table unless the maker approves it for aluminum.
Frequently Asked Questions
Can you cut aluminum with a plasma cutter?
Yes. Plasma cuts electrically conductive aluminum quickly when the machine is rated for the thickness and you use the right consumables, clean dry air and a steady travel speed. Expect an oxidized edge that needs cleanup before welding.
What should a plasma cutter be set at for aluminum?
Use the amperage, pressure, height and speed on the cut chart for your machine. One Hypertherm Powermax45 mechanized chart lists 45 amps for 1/8 inch aluminum, but that is not a setting for every cutter.
What gas do you use to plasma cut aluminum?
Portable air-plasma cutters use clean, dry air. Multi-gas systems may use nitrogen, nitrogen with a water shield, or a hydrogen mix for thick plate, depending on the maker’s process.
Are the fumes from plasma cutting aluminum dangerous?
Cutting produces metal oxide fumes, and paint or coatings add more. Use local exhaust or good cross ventilation, avoid breathing the plume and follow OSHA and your employer’s respiratory guidance.
Can I plasma cut aluminum on a water table?
Only on a table the manufacturer approves for aluminum. Hypertherm warns against cutting aluminum under water with H-35 or H-2 gas mixtures because hydrogen can collect.
Related Aluminum Plasma Cutting Guides
- Plasma cutter for aluminum: how to choose and use one
- Settings to plasma cut 1/8 inch aluminum
- Plasma cutting amperage for aluminum by thickness
- Aluminum plasma cutting chart: speed, height and gas
Conclusion
Plasma cutting aluminum goes well when you follow the chart for your machine, keep the air dry, move at a steady speed and test on scrap first. Fix problems one setting at a time, and treat fumes and hydrogen risk as part of the setup.
