We collect basic website visitor information on this website and store it in cookies. We also utilize Google Analytics to track page view information to assist us in improving our website.
We collect basic website visitor information on this website and store it in cookies. We also utilize Google Analytics to track page view information to assist us in improving our website.
If you’re passionate about metal cutting or just keen to learn more, you’ve landed in the right place.
For over 38 years, Amber Steel has been at the forefront of metal cutting services, specializing in laser cutting, flame cutting, and plasma cutting. Our expertise has carved a niche in this cutting-edge industry, delivering precision and excellence across industrial projects big and small.
In our blog, we’ll share a mix of useful tips, innovative applications, our thoughts on sustainability in steel cutting, and more. Expect stories from the cutting floor, insights into how our processes can streamline projects across industries, and a few lessons we’ve learned along the way.
While we keep some of our trade secrets under wraps, this blog is designed to offer valuable nuggets of wisdom that you simply won't find anywhere else. Whether you’re a professional in the industry or someone fascinated by the possibilities of metal cutting, you'll find something of value here.
So, stick with us as we delve into the finer points of metal work. We’re glad to share our insights and lead discussions that matter to our industry.
How precision metal cutting propels the aerospace industry, from constructing lighter frames to enhancing aerodynamics.
The role of advanced metal cutting in automotive manufacturing, driving innovations in vehicle design and efficiency.
All about the robust and versatile process of flame cutting, ideal for tackling thicker metals with precision and ease.
Discover the art of crafting metal furniture, where cutting techniques meet design to create both functional and aesthetic pieces.
A behind-the-scenes look at the mechanics of metal cutting technologies and the science that makes them tick.
Laser cutting is where extreme precision meets efficiency, allowing for intricate designs and clean finishes.
The critical role of precise steel cutting in developing reliable and intricate medical devices.
How steel cutting supports the oil and gas industry with components that withstand extreme environments and pressures.
Known for its speed and versatility, plasma cutting slices through conductive metals with hot plasma.
Safety first! Tips and insights on maintaining a safe environment while handling powerful metal cutting equipment.
The backbone of construction, where steel fabrication and cutting technologies create frameworks that shape skylines.
Sustainability
A look at sustainability in metal cutting, focusing on practices that reduce waste and conserve energy to protect our planet.
You wouldn't use a chainsaw to slice a loaf of bread, right? And you certainly wouldn’t use a bread knife to fell a tree. The same idea applies to metal: different thicknesses call for different cutting tools. When it comes to thick carbon steel plate (1 inch (25.4mm) thick and up), flame cutting is the heavy-duty tool that gets the job done.
Flame cutting handles thicknesses between 6 inches(150mm) and 12 inches (300mm) with standard equipment. With specialized setups, it can even cut steel plates over 12 inches thick!
Here, we break down why flame cutting is the go-to method for tackling those thick steel projects and compare it with other cutting techniques like laser and plasma.
To really appreciate why flame cutting excels at slicing through thick steel, it helps to understand the science behind it.
Contrary to how it looks from the outside, flame cutting isn’t only about melting metal with a hot flame. It involves a carefully controlled chemical process that harnesses the power of oxidation.
Let’s look at the process step-by-step and break down why it’s perfect for cutting thick steel plate.
The first step in the flame cutting process is preheating the steel with a flame cutting torch.
The cutting torch burns a mix of fuel (like propane or natural gas) and oxygen to create a very hot flame. The flame transfers heat to the steel through both conduction (directly from the flame to the steel's surface) and convection (hot gases from the flame flowing over the steel.)
The main goal of preheating process is to make the steel hot enough to catch fire and keep burning for as long as it’s fed with oxygen. The point where this occurs is called the ignition temperature, which is between 1,150 and 1,250 °C for mild steel.
The preheating flame also as a protective barrier that shields the oxygen stream from the surrounding atmosphere. The oxygen used for flame cutting needs to be at least 99.5% pure – even a 1% drop in purity can reduce cutting speed by about 15%.
With the steel preheated to its ignition temperature, the stage is set for the core of the flame cutting process: oxidation.
Think of rust. When iron or steel is exposed to air and water, it rusts. This rust is iron oxide, and it forms because the iron loses some of its tiny parts (electrons) to oxygen in the air. This process of losing electrons is called oxidation.
In flame cutting, we use this "rusting" process to our advantage. After preheating the thick steel plate steel, we blow a strong stream of pure oxygen onto it to cause rapid oxidization.
The oxidation of iron is highly exothermic, meaning it releases a substantial amount of heat. This additional heat helps cut the steel even faster. It's like the steel is helping to cut itself!
When the hot steel meets the oxygen, they react and create a substance called iron oxide (FeO), commonly referred to as slag. Slag has a much lower melting point than steel.
As the iron oxidizes, the molten slag is continuously blown away by the force of the oxygen jet. This keeps the oxygen in contact with the metal, allowing it to cut through even very thick steel.
This three-step process – preheating, rapid oxidation, and continuous slag removal – is what makes flame cutting so effective on thick steel plates. The self-sustaining nature of the oxidation reaction allows flame cutting to slice through thick steel with speed and precision.
With the above in mind, it’s easy to see how flame cutting offers major benefits for manufacturers working with thick steel.
Efficiency: One of the biggest advantages of flame cutting is its speed, even when dealing with very thick steel. This impressive speed is due to the way the cutting process itself generates heat. Flame cutting's speed allows for faster production times, increasing the overall efficiency of manufacturing processes.
Precision: While flame cutting is often associated with rough cuts, it can achieve a surprising level of precision, even in thick steel. The focused heat and oxygen create a very narrow cut in the steel, minimizing the amount of material wasted.
Heat-Affected Zone (HAZ): When cutting steel with any thermal process, it's important to consider the Heat-Affected Zone (HAZ). This is the area around the cut where the heat changes the properties of the steel. Flame cutting create a smaller HAZ compared to other methods, especially when cutting thick steel, because the rapid reaction between the steel and oxygen generates intense heat specifically at the cutting point – not into the surrounding metal.
Cost-Effectiveness: When it comes to cutting thick steel, flame cutting often offers the most economical solution. It requires less energy compared to other cutting techniques, and uses readily available, affordable gases like propane and oxygen. As we've discussed, flame cutting also maintains impressive speeds even with very thick steel; this speed translates to faster production times, reducing labour costs and increasing overall output.
While flame cutting is a powerhouse for thick, low-to-medium carbon steel, it's not a universal solution for all metal cutting needs.
Certain metals simply aren’t compatible with flame cutting due to their properties:
Aluminum, copper, brass and bronze oxidize readily, but their oxides have a higher melting point than the base metal itself. The molten oxide forms a hard layer on top that prevent the oxygen jet from cutting through.
Stainless steels contain chromium and nickel, which also form oxides with very high melting points that form a hard layer blocking the cutting action.
Lead, tin, and zinc have melting points lower than the preheating temperature required by flame cutting. These metals would essentially melt away before a proper cutting action could take place.
Flame cutting also isn't ideal for very thin sheets of metal (generally below 3/8 to ½ inch). This is because thin sheets require a very high cutting speed to achieve a good cut, and the intense preheating needed can lead to warping or distortion.
For thinner materials, and/or above-mentioned metals, plasma cutting or laser cutting are often preferred due to their ability to provide precise and controlled cuts with minimal heat input.
While laser, plasma, and flame cutting each have their place in metal fabrication, flame cutting offers distinct advantages for thick steel.
Laser cutting uses a powerful beam of light to melt or vaporize metal. It's very precise, especially for thin materials. However, it faces some challenges when cutting thick steel.
The laser beam loses energy as it cuts deeper into thick steel, which makes it harder to maintain a clean and consistent cut. The cut made by the laser can have a wider, tapered kerf in thick steel. This can affect the accuracy of the final product, especially when cutting more complex shapes.
Cutting thick steel with a laser is also slower because the laser takes longer to penetrate through thicker material. This exposes a wider area of the workpiece to high temperatures, increasing the HAZ.
Outside of thick steel plate, laser cutting is an incredibly fast and precise cutting method for a wide range of applications. Its precision is unbeatable, particularly in thinner materials. Learn more about how laser cutting shapes up against traditional cutting methods.
While plasma cutting is a versatile tool, it has some limitations when it comes to thick steel plates.
The plasma jet, which is the hot, ionized gas used to cut metal, can spread out as it cuts through thick material. This creates a wider cut with a slanted edge, which might not be suitable when you need very precise and clean cuts.
Like laser cutting, the plasma arc takes longer to cut through thick steel, creating a larger HAZ. Flame cutting is faster than both plasma and laser cutting for thick plates.
Cutting extremely thick steel (over 5 inches) with plasma can be even more challenging. The plasma jet can lag the torch, resulting in an angled cut. This so-called lag angle requires special techniques and equipment to control.
With that said, aside from thick steel plate, plasma cutting is an incredibly versatile cutting method. Learn more about how plasma cutting works and its advantages.
Flame cutting is a proven and powerful cutting method for carbon steel plates upwards of 1 inch thickness. It offers a combination of efficiency, precision, and cost-effectiveness that makes it an easy choice for many industries.
We use advanced flame cutting technology to cut your steel parts according to your exact needs. Whether you need simple shapes or complex designs, we can deliver precise cuts that are ready for the next manufacturing step.
With over 35 years of experience, Amber Steel is a trusted leader in the steel cutting industry. We are committed to providing reliable service and high-quality results.
Contact us today speak to our experienced team. We’ll help you find the best flame cutting solutions for your business.
