An oxyfuel torch can only cut mild steel and wrought iron, provided the metal is free of rust or paint. A torch cannot cut high carbon steel, cast iron, stainless steel, or any type of non-ferrous metal, like copper and aluminum.

Plasma can cut both thick and thin metal.
Though both processes can technically cut a wide range of thicknesses, it isn’t practical to cut thin metal with oxyfuel because it is less precise, creates a large heat affected zone which can warp the material, and is a much slower process. For this reason, oxyfuel is generally used on metal greater than 50 mm (2″) in thickness.

Plasma is safer.
Oxyfuel requires the use of a highly flammable fuel gas and an open flame. Once the torch is lit, the flame stays on until the system is manually turned off. Plasma does not use a fuel gas and its arc automatically extinguishes when the torch is removed from the metal, leading to a safer job site.

Plasma is faster.
At a minimum, a plasma cutter is 12 times faster on thinner materials and twice as fast as an oxyfuel torch when cutting metals up to 25 mm (1″) in thickness. In addition, preheating is not required with plasma as it is with oxyfuel. Piercing is also faster with plasma. It can take 30 seconds to pierce 16 mm (2/3″) thick steel with oxyfuel. Plasma takes less than two seconds.

Plasma costs less to operate.
Plasma cutters cost less to operate since you do not need to worry about refilling and transporting flammable gas cylinders.

Plasma provides more precise cuts.
It is possible to achieve very good cut quality with both processes provided the oxyfuel operator is experienced. Overall though, a plasma cutter will produce more precise and cleaner cuts with better angularity, a thinner kerf, a smaller heat affected zone, and zero to no dross.

Plasma is easier to use.
The ability to get a good result with an oxyfuel torch is highly dependent on the operator. Oxyfuel cutting is an art form that requires practice to perfect since operators need to set and maintain flame chemistry while holding a steady distance from the surface being cut. Plasma on the other hand is much more forgiving and quickly mastered. The Hypertherm Powermax SYNC^® series of air plasma cutters with its single-piece cartridge consumable are even easier to use.