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Plasma Cutting Guide: Which Metals Can Be Cut (Mild Steel, Stainless, Aluminum, Galvanized) & Maximum Thicknesses

Plasma cutting is a precise, high-speed thermal process that uses ionized gas to cut electrically conductive metals, outperforming traditional methods like grinding or oxyacetylene torches in efficiency and edge quality. It excels on mild steel, stainless steel, and aluminum, with each requiring tailored settings and gases for optimal results. Mild steel is the easiest and most common, though galvanized versions demand strict safety measures—such as PAPR respirators and fume extraction—to avoid zinc oxide fumes causing metal fume fever. Stainless steel benefits from nitrogen gas and CNC precision to minimize oxidation and ensure clean cuts. Aluminum requires fast travel speeds to prevent warping due to its high thermal conductivity. Maximum thickness depends on the machine: “clean” cuts offer high-quality results up to the recommended capacity (e.g., 5/8” on a Powermax45), while severance allows thicker penetration with rougher edges and more cleanup. Proper technique, PPE, and manufacturer cut charts ensure safe, effective performance across applications.