Add Cutting to Your Field Kit

Welding and cutting go together. In the field, the ability to cut steel, aluminum and stainless
cleanly—without compressed gas cylinders or expensive gear—saves hours. A plasma cutter
powered by the auxiliary output of an engine driven welder is one of the most
productive combinations a crew can carry.

How Plasma Cutting Works

A plasma cutter sends a high-velocity jet of ionized gas through a nozzle, creating an electric arc
that melts and blows away metal. It cuts any conductive metal—steel, stainless, aluminum,
copper, brass—with minimal heat-affected zone and no oxidation like oxy-fuel. The result is a
clean, narrow kerf that needs little cleanup.

Matching Plasma Cutter to Engine Welder Auxiliary Power

  • Auxiliary output: Most engine driven welders provide
    8–15 kW of 120/240 VAC auxiliary power. Check the continuous rating, not just peak.
  • Plasma power demand: A 120 V plasma cutter cuts up to ~6 mm; a
    240 V unit cuts 10–25 mm depending on amperage.
  • Duty cycle match: Plasma cutters draw high current at cut start; ensure the
    auxiliary can handle surge and sustained load.
  • Clean power: Some engine welders have dirty auxiliary output (THD); check if
    the plasma cutter requires clean sine wave. Inverter plasma cutters are usually tolerant.

Setup in the Field

  • Ground connection: Attach the work clamp directly to the cut piece or a clean
    section of the same metal. Poor ground causes erratic arc and bad cuts.
  • Air supply: Most field plasma cutters use compressed air at 4–8 bar.
    Use a portable compressor or the engine welder’s onboard air (if equipped).
  • Consumables check: Electrode, nozzle, swirl ring and shield cap wear with use.
    Inspect and replace before cutting quality drops.
  • Dry air: Moisture in the air line ruins consumables fast; use a moisture filter
    or water trap.

Cutting Technique

  • Standoff vs. drag: Drag tips touch the plate (good for thin material); standoff
    tips hover 3–5 mm for thicker plate and longer consumable life.
  • Travel speed: Move at the speed that produces a clean, sparks-trailing cut. Too
    fast leaves a bevel; too slow wastes consumables and widens the kerf.
  • Pierce: Start at the edge or pierce at full power; wait for the arc to penetrate
    before moving. Piercing too fast damages the nozzle.
  • Direction: Cut clockwise for outside shapes so the good side is on the right;
    counterclockwise for inside holes.

What You Can Cut in the Field

  • Steel plate: Up to 25 mm with a 240 V / 40–50 A plasma on
    engine welder auxiliary.
  • Stainless steel: Clean cut, no oxidation; great for handrail and tank work.
  • Aluminum: Fast, clean cut without the molten mess of oxy-fuel.
  • Grating, expanded metal, pipe: Plasma excels at shapes that oxy-fuel
    struggles with.
  • Bolt and rivet removal: Cut off frozen fasteners without damaging surrounding
    material.

Safety

  • Eye protection: Plasma arc is intense UV; use a shade 5–8 lens (not a
    welding helmet unless cutting very thick).
  • Fire and sparks: Plasma throws less spark than oxy-fuel but still ignites
    flammables; clear the area and use blankets.
  • Electric shock: The arc is high-frequency; keep hands dry and stand on dry
    ground.
  • Fumes: Cutting galvanized or coated steel releases zinc and other toxic fumes;
    ventilate or use respirator.

Conclusion

Plasma cutting turns an engine driven welder into a complete fabricate-and-repair
station. Match the cutter to the auxiliary power, keep air dry and consumables fresh, and you can cut
steel, aluminum and stainless anywhere. Explore our plasma cutting equipment and
field kits to build a capable mobile cutting setup.

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