There are several signs of worn consumables; the experienced operator can often tell by sound or color of the arc or subtle changes in torch height that indicate parts wear. However, the best way to judge the condition of the torch parts is to periodically check the cut edge quality of the metal, and check the torch parts when the cut begins to deteriorate. Keep a record of the average parts life over time (in number of starts or arc-on time) and develop guidelines for expected parts life based on the amperage, material and thickness.
Once average parts life is established the operator will know when to check and or replace the parts--preventing a catastrophic failure. Consumable life in air plasma cutting depends on various factors including cutting amperage, cutting speed, air quality, humidity, air pressure and operator skill.

There are several signs of worn consumables; the experienced operator can often tell by sound or color of the arc or subtle changes in torch height that indicate parts wear. However, the best way to judge the condition of the torch parts is to periodically check the cut edge quality of the metal, and check the torch parts when the cut begins to deteriorate. Keep a record of the average parts life over time (in number of starts or arc-on time) and develop guidelines for expected parts life based on the amperage, material and thickness.
Once average parts life is established the operator will know when to check and or replace the parts--preventing a catastrophic failure. Consumable life in air plasma cutting depends on various factors including cutting amperage, cutting speed, air quality, humidity, air pressure and operator skill.