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Plasma Cutting System VS Flame Cutting System

Last Updated on May 12, 2022 by 6 Min Read

Plasma Cutting System VS Flame Cutting System

Plasma Cutting System VS Flame Cutting System

Compared to plasma cutting systems, the flame cutting system, or oxyfuel cutting torch, is a practical choice for mild steel over 1 inch thick, whereas a plasma torch will work well for thinner materials, whether ferrous or non-ferrous.

To start, let’s wrap our heads around how does the two systems work.

How Does a Plasma Cutter Work?

Plasma cutters use a gas like compressed air, nitrogen, oxygen, etc. and send an electric arc through that gas. This turns the gas to plasma, and it rapidly blasts through metal to cut it at high speeds.

That high speed plasma is called the “plasma jet”, and it almost instantly heats the metal to around 30,000-40,000 °F and at extremely high speeds like 20,000 feet per second – this is basically why plasma cutter is so fast. That’s a pretty insane temperature.

Essentially, plasma cutting just incinerates the material in a controlled way.

Additionally, there is a curtain of gas that shields the cutting area and improved cut quality. It helps keep the cut straighter and thinner.

How Does a Flame Cutting Torch Work?

If you think that a flame cutting torch simply melts the material away, that’s only half the answer.

A flame cutting torch works by adding a blast of oxygen to the flame which oxidizes the steel and turns it into slag. Essentially, it’s a chemical reaction between the oxygen and the steel. The heat just makes this reaction happen really fast.

Think of it almost as a super fast and controlled rusting.

The flame preheats the steel up to about 1800 degrees F, and the pressurized oxygen both oxidizes and blasts away the material.

So essentially, the thickness of mild steel you can cut is equal to the amount you can heat up and blast with a stream of pressurized oxygen. With larger units, this can get pretty deep – you can cut steel well over a foot thick. It just takes a while.

Plasma Cutting System VS Flame Cutting System

Plasma Cutting SystemFlame Cutting System
Cuts steel, iron, stainless, aluminum, brass, anything that will conduct electricityAble to cut mild steel and iron, does a hack job on other materials that are thin
Rarely able to cut through more than 2″ thick steel, but the sweet spot is usually 3/4″ and under for large machinesCan cut extremely thick metal – often over 12″ thick – depending on the size of the nozzle
Narrow KerfWider kerf
More expensive system to buyMore economical system to buy
Cleaner cut, often only a wire brush is needed to dress the edgesRougher cut, needs more cleanup, likely with a grinder
Really fast cuttingSlower cutting
The thickness of material that can be cut is determined by the size of the machine.Change the nozzle for different thicknesses of material

Let's compare the differences between plasma cutting system and flame cutting system:


Plasma cutting really shines in this one – since the plasma is just electrified gas, a plasma cutter will basically cut any material that conducts electricity. Aluminum, steel, stainless, brass, copper, you name it, plasma makes quick work of it.

For flame cutting torches, the answer is a little more complicated. They’re intended for mild steel, but there’s an asterisk on that statement.

If you’ve played around with one yourself, you’ll know that you actually can cut through thinner aluminum and stainless, as well as other materials. But the cuts will be ugly and messy. Here’s why:

The process is intended to oxidize the metal. Stainless and aluminum don’t really oxidize much. So instead of turning the metal into slag, you’re actually just melting a gap in the material, and the force of the flame is pushing it out. You can’t cut these materials when they’re thick, this more so happens for sheet metal.

So the technical answer is that you can get through these other materials if they’re thin, but it’s gonna be ugly. Also, the surrounding metal will be really affected by the heat, which will mean that you can get some crazy warping (like with stainless) or a massive heat affected zone (like with alloy steel). Basically, it’s just mild steel that’s recommended for cutting torches.


Oxyfuel torches eat thick steel for breakfast. If you’re trying to get through a 4″ thick steel axle, then the cutting torch is your tool.

The really heavy duty ones can cut through as much as four feet of solid steel. Honestly, it’s pretty unlikely that you’ll encounter this on a regular basis, but you never know, right? The part to remember is that you can slice through an engine block, as long as it’s made of iron and not aluminum.

For most units, though, you can expect to have a max thickness of one foot if you have a big torch nozzle. The smaller the nozzle, the thinner the kerf, and the thinner the material you can cut.

Plasma torches don’t cut nearly as thick. The really heavy duty ones can get up to about 2-3/4″ thick, but it’s not too likely that you’ll get your hands on one of those. The standard industrial ones cut more so around 1″ thick material, and the hobby machines tend to max out at about 1/4″ or 3/8″.


Again, plasma shines. Since it’s working with such insane heat, it’s a really fast cutter. Apples to apples, you’ll never keep up to plasma with a cutting torch.


The flame cutting system is definitely the most portable in terms of being able to strap it down in your truck and slicing up a tractor in the middle of the field. You can take it anywhere that you can carry it.

The plasma cutter is (generally) a smaller unit, so it’s easy to carry, but you need to be able to plug it in. The smaller hobby units are usually around 20-30 pounds. If you’re working in shops, it’s not a problem, but if you’re working on a farm, it can be annoying.


Both systems have consumables – the tips will wear out and there will be small replacement parts. This isn’t a major expense, though.

This is one area where I prefer plasma, though: For oxyfuel, you need to refill your gas bottles. For plasma, you generally only need compressed air.

Technically, the plasma uses a fair bit of electricity


Flame torches are pretty straightforward, just pick out the right size nozzle for the job. The only other thing worth making sure of is that you have flashback arrestors installed so nothing goes boom.

There are a few terms worth knowing, though, when you’re looking at buying a plasma torch. Here’s an overview and an explanation of what they mean.


This is a loaded question – both systems have things that the other can’t do.

For oxy acetylene, different torches (welding, cutting or rosebud) can let you weld, heat, hardface, cut, solder, braze, blend and gouge. For cutting, you’re mainly limited to mild steel, but you can weld most metals with it.

For plasma, you can commonly find 3-in-1 little units that will let you cut, TIG, and arc weld. Aside from that, though, a plasma cutter is for cutting.

Pilot Arc

This is basically a little wire that keeps the plasma running when it’s not close to the workpiece.

It’s practical for applications like working with expanded metal or mesh. It will keep the machine running consistently for interrupted cutting.

If you’re just wanting to get some work in the garage done, you won’t really need this, and you won’t see much benefit if you’re only cutting sheet metal or slicing apart a car. If you’re doing a lot of mesh-type work, though, it does speed up the process.

High Frequency

This is referring to what’s used to start the plasma torch, and it’s similar with a welder. Basically, a high frequency, high voltage current is powered through the torch which makes it easier to start cutting.

This makes the piercing point smaller, cleaner, and easier, and it’s handy for thicker materials.

Generally speaking, you don’t need this for hobby machines that are used for thin sheet metal. If anything, a good practice is to pierce the material slightly off the line where you want to cut, then sweep the plasma on to the cut line

Which metal cutting system should you get?

Here’s when you should get a flame cutting torch:

1. You’re working with mild steel.

2. You work with heavy equipment.

3. You want to cut heavy duty axles and big chunks of steel.

4. You like to have at least one of every tool.

5. Versatility is important – you want to not only cut, but weld and heat up metal.

6. You don’t need to cut sheet metal and plates quickly, but you want to have it as an option.

7. You’d like something that you can take out to the middle of a field to work with – electricity not required.

Here’s when you should get a plasma cutter:

1. You want to slice a truck frame into pieces.

2. You’re interested in fabrication.

3. You like to have at least one of every tool.

4. You want to be able to cut sheet metal and plates quickly.

5. You’re an artist and make sheet metal sculptures.

6. You’re working with a wide variety of materials.

7. Your main focus is on cutting, and versatility is secondary.

8. Mobility isn’t too important, you’ll be working primarily in shops.

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