Titanium Plasma Cutting and CNC Machining for Energy Sector Components

Background: Energy Sector Component Requirements

Energy sector components, such as turbine housings, pump components, and heat exchangers, require corrosion-resistant, high-strength titanium. These components often feature complex cutouts, thick walls, and precise mounting surfaces. Plasma cutting provides rapid shaping of titanium sheets, while CNC machining ensures precise functional features.

In this project, the customer required titanium plates and structural components for energy machinery. Titanium plasma cutters were used for fast near-net-shape cutting, followed by CNC machining for finishing holes, slots, and flanges.

Material Selection and Machinability Considerations

Titanium alloys were selected for high strength, corrosion resistance, and thermal stability. Machinability challenges included:

• Low thermal conductivity causing heat buildup

• Work hardening tendencies

• Maintaining flatness on thick plates

Titanium plasma cutting enabled initial shape separation without excessive thermal distortion. CNC machining finalized functional features with high precision.

Titanium Plasma Cutting Process

Plasma cutting operations included:

• Securing titanium sheets on precision fixtures

• Adjusting plasma cutter speed and power for thickness

• Cutting near-net-shape blanks for CNC finishing

Edges were clean, and minimal taper ensured accurate fit during machining.

CNC Titanium Machining for Energy Components

CNC operations included:

• Milling for flanges, slots, and pockets

• Drilling and threading for assembly points

• Finishing surfaces to tight tolerances

High-speed machining titanium parameters were optimized for dimensional accuracy and surface integrity.

Dimensional Accuracy and Surface Quality

Critical dimensions were held within ±0.01 mm. Surface finishes met industry standards for energy sector assemblies. CMM inspection confirmed flatness, hole alignment, and geometric accuracy.

Heat Management and Stress Control

Optimized plasma cutting reduced heat input. High-speed machining titanium minimized thermal distortion. Selective stress relief was applied for thick sections requiring precise flatness.

OEM Support and Engineering Collaboration

Engineering teams collaborated to:

• Plan plasma cutting paths for efficient material utilization

• Sequence CNC machining operations for precision features

• Validate prototypes prior to full-scale production

CAD/CAM tools such as SolidWorks, UG, and CATIA were used. Supported drawing formats included STEP, DWG, DXF, IGS, STL, and PDF.

Applications in Energy Sector

Titanium plasma cutting combined with CNC machining is widely used for:

• Turbine housings

• Heat exchangers and pump components

• Structural assemblies requiring corrosion resistance and precision

This integration ensures fast production of high-quality, durable titanium parts.

Conclusion

This case demonstrates how titanium plasma cutting combined with CNC machining produces energy sector components with high precision and minimal distortion. Optimized cutting parameters, high-speed machining, and inspection protocols ensure reliable, high-quality titanium parts for demanding energy applications.