XPR460

Hypertherm XPR460 consumables are multi-part mechanized plasma consumable sets for high-definition cutting of mild steel, stainless steel and aluminum. They are selected by material, amperage and gas process, helping maintain cut quality, piercing performance and reliable productivity on XPR460 plasma cutting systems.

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about the consumables for the
XPR460

XPR460 consumables are genuine Hypertherm mechanized plasma consumables designed for the XPR460 high-definition plasma cutting system. Unlike the Powermax SYNC range, the XPR460 uses multi-part consumable sets selected according to material, amperage and gas process. Correct consumable selection is essential for cut quality, piercing performance, consumable life and repeatable production results.

Available XPR460 consumables support cutting applications for mild steel, stainless steel and aluminum, with process options including O2/Air, N2/H2O and advanced mixed-gas processes such as OptiMix H2-Ar-N2/N2. Consumable parts include items such as shield caps, shields, nozzle retaining caps, nozzles, swirl rings, electrodes and water tubes, depending on the selected process and amperage.

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System information

Benefits

Widest versatility expands capabilities

  • Provides superior cutting versatility for mild steel, stainless steel, and aluminum
  • Offers the widest range of cutting power for various metals and thicknesses
  • Delivers high-quality, consistent cutting on imperfect metal surfaces, including paint and rust
  • XPR automated gouging minimizes or eliminates grinding compared to carbon arc gouging, producing weld-ready parts faster with cleaner gouge profiles

Optimized productivity drives lower operating costs

  • Maximum power optimizes productivity by delivering higher cut quality, thicker cutting capability, and faster cutting speeds

  • Argon-assist technology enables piercing and edge-starting on the thickest mild steel and stainless steel

  • Cuts with oxygen up to 460 Amps, delivering the best cutting outcomes on mild steel

  • Exclusive Arc Response Technology™ intervenes in adverse events to preserve consumable life and prevent torch damage

  • The web interface tool can be accessed via Wi-Fi and Ethernet LAN in the power supply for system monitoring and service

  • Built-in IIoT (Industrial Internet of Things) via Ethernet LAN and MTConnect® enables remote data access for smarter monitoring from anywhere in the world

  • Manual Set-Mode is ideal for straightforward applications like gouging and off-table beveling; it retains your last setup for faster, repeatable workflows and simplifies set up and operations without the need for CNC/PLC integration



Precision cutting reduces secondary operations

  • Delivers excellent part-to-part consistency over consumable life from the first cut to the last

  • Provides a smooth surface, low angularity, and minimal to no dross for clean parts off the table

  • XPR® embedded technology improves 45-degree bevel cut quality on thick material making the welding process more efficient

  • Exclusive SureCut™ technology delivers improved outcomes by automatically embedding advanced cutting capabilities into our plasma cutting process

 

Maximum open-circuit voltage

360 VDC

Maximum output current

460 A

Maximum output power

102 kW

Output voltage

50–222 VDC

100% duty arc voltage

222 V

Duty cycle rating

100% at 102 kW, 40° C (104° F)

Operational ambient temperature range

-10° C–40° C (14° F–104° F)

Power factor

0.98 at 102 kW

Cooling

Forced air (Class F)

Insulation

Class H

EMC emissions classification (CE models only)

Class A

IP rating

IP21

Unit dimensions

H = 124.8 cm (49.12″)

L = 123.8 cm (48.75″)

W = 90.5 cm (35.64″)

Lift points

Top lift eye weight rating 680 kg (1,500 lb.)

Bottom life truck slots

 

Cut chart thickness

Mild steel

mm

inches

Production pierce capacity (air shield gas)

50

2

Enhanced pierce capacity (argon-assist piercing)*

64

2 1/2

Production severance

90

3 1/2

Enhanced severance

102

4

Stainless steel

 

 

Production pierce capacity

38

1 1/2

Enhanced pierce capacity (argon-assist piercing)*

64

2 1/2

Production severance

90

3 1/2

Enhanced severance (argon-assist cutting)*

130

5

Aluminum

 

 

Production pierce capacity (N2 shield gas)

38

1 1/2

Enhanced pierce capacity (argon-assist piercing)*

50

2

Production severance

80

3

* Argon-assist technology for thicker piercing and thickness severance cutting is available with CorePlus, VWI, OptiMix gas consoles.

 

This does not represent a complete list of processes or thicknesses that are available.

Console

Cutting gases

Current (A)

Cut chart
thickness
(mm)

Approximate cutting
speed (mm/min)

Cut chart
thickness
(in)

Approximate cutting
speed (ipm)

Mild steel

Core™, CorePlus™, VWI™, and OptiMix™

O2 plasma

O2 shield

30

0.5

5348

0.018″

215

3

1153

0.135″

40

5

726

3/16″

30

O2 plasma

Air shield

50

3

3820

0.105″

155

5

2322

3/16″

95

8

1369

5/16″

55

O2 plasma

Air shield

80

3

5582

0.105″

225

6

3048

1/4″

110

12

1405

1/2″

55

O2 plasma

Air shield

130

3

6502

0.135″

240

10

2680

3/8″

110

38

256

1 1/2″

10

O2 plasma

Air shield

170

6

5080

1/4″

200

12

3061

1/2″

115

25

1175

1″

45

60

152

2 3/8″

6

O2 plasma

Air shield

220

10

3715

3/8″

150

18

2369

5/8″

110

60

158

2 1/2″

6

O2 plasma

Air shield

300

12

3940

1/2″

155

25

1950

1″

75

N2 shield

300

50

560

2″

21

80

165

3″

7

O2 plasma

Air shield

460

12

4826

1/2″

190

38

1372

1 1/2″

54

60

559

2 1/2″

22

102

130*

4″

5*

Stainless steel

Core, CorePlus, VWI, and OptiMix

N2 plasma

N2 shield

40

0.8

6100

0.036″

240

3

2683

0.105″

120

6

918

1/4″

32

VWI and OptiMix

F5 plasma

N2 shield

80

3

4248

0.135″

140

6

1916

1/4″

70

12

864

1/2″

34

OptiMix

H2-Ar-N2 plasma

N2 shield

170

10

1975

3/8″

80

12

1735

1/2″

65

38

256

1-1/2″

10

300

12

2038

1/2″

80

25

1040

1″

40

50

387

2″

17

75

162

3″

6

VWI and OptiMix

N2 plasma

H2O shield

300

12

2159

1/2″

85

25

1302

1″

50

50

434

2″

15

N2 plasma
H2O shield

460

16

2896

5/8″

115

38

1172

1-1/2″

46

60

564

2-1/2″

20

OptiMix

H2-Ar-N2 plasma

N2 shield

460

18

2337

5/8″

92

38

966

1 1/2″

38

60

534

2 1/2″

21

127

77*

5″

3*

Aluminum

Core, CorePlus, VWI, and OptiMix

Air plasma

Air shield

40

1.5

4799

0.036″

240

3

2596

1/8″

85

6

911

1/4″

32

VWI and OptiMix

N2 plasma

H2O shield

80

3

3820

1/8″

140

6

2203

1/4″

80

10

956

1/2″

28

N2 plasma

H2O shield

130

6

2413

1/4″

95

10

1702

3/8″

70

20

870

3/4″

35

N2 Plasma

H2O shield

300

12

2286

1/2″

90

25

1302

1″

50

50

524

2″

20

OptiMix

H2-Ar-N2 plasma

N2 shield

300

25

2056

1″

80

50

391

2″

15

H2-Ar-N2 plasma

N2 plasma

460

18

2337

5/8″

92

38

1372

1 1/2″

38

60

559

2 1/2″

21

80

762

3″

30

VWI and OptiMix

N2 plasma
H2O shield

460

16

3536

5/8″

140

38

1605

1-1/2″

63

50

1175

2″

45

*Argon-assisted cutting

 

Torches and consumables

Nozzles and electrodes are available in various quantities. Please contact an authorized Hypertherm distributor to place your consumables order. Your consumables may not look exactly like the pictures.

Part number
Standard		Part number
Standard
Bevel/Robotic		Part number
Bevel/Robotic		Description
428383428825428831*Lead: 6.6′
428384428826428832*Lead: 8.2′
428385428827428833*Lead: 9.8′
428386428828428834*Lead: 11.5′
428824428829428335*Lead: 13.1′
428387428830428836*Lead: 4.8′
 428978**428979**Lead: 20′**
 428916 Lead: Thru arm robotic 11.5′
 428918 Lead: Thru arm robotic 14.8′
420500  Torch mounting sleeve: Standard
420501  Torch mounting sleeve: Short
420502  Torch mounting sleeve: Extended
 420788 Rotational torch mounting sleeve: Short
 420789 Rotational torch mounting sleeve: Medium
 420790 Rotational torch mounting sleeve: Extended
420220  Quick-disconnect torch receptacle
420221  Quick-disconnect XPR torch
420368  Water tube

* Bevel/Robotic leads sets 428831-428836 include an extended 1.2 m (48″) strain relief.
** The 6 m (20′) lead is compatible only with console gas assemblies that are 7.5 m (24.6′) or less.

AmperageProcessShield capShieldNozzle retaining capNozzleSwirl ringElectrodeWater tube
30 AO2/O2420200420228420365420225420407420222420368
50 AO2/Air420200420237420365420234420233420231420368
80 AO2/Air420200420246420365420243420242420240420368
130 AO2/Air420200420255420365420252420242420249420368
170 AO2/Air420200420513420365420261420260420258420368
220 AO2/Air420200420273420365420270420406420276420368
300 AO2/Air420200420491420365420279420406420276420368
460 AO2/Air420200520002420365520001420819420834420368

AmperageProcessShield capShieldNozzle retaining capNozzleSwirl ringElectrodeWater tube
40 AN2/N2420200420291420365420288420314420303420368
Air/Air420200420291420365420288420314420294420368
60 AN2/N2420200420309420365420297420323420303420368
F5/N2420200420309420365420297420323420303420368
N2/H2O420200420300420365420296420323420303420368
Air/Air420200420309420365420297420323420294420368
80 AN2/N2420200420309420365420306420323420303420368
F5/N2420200420309420365420306420323420303420368
N2/H2O420200420300420365420290420323420303420368
Air/Air420200420309420365420306420323420294420368
130 AN2/N2420200420318420365420315420314420356420368
H2-Ar-N2/N2420200420318420365420315420323420356420368
N2/H2O420200420469420365420315420314420356420368
170 AN2/N2420200420327420365420324420314420356420368
H2-Ar-N2/N2420200420327420365420324420323420356420368
N2/H2O420200420472420365420324420314420356420368
Air/Air420200420513420365420524420260420258420368
300 AN2/N2420200420362420365420359420323420356420368
H2-Ar-N2/N2420200420362420365420359420358420356420368
N2/H2O420200420475420365420359420323420356420368
460 AH2-Ar-N2/N2420200420998420365420996420358420997420368

Mild Steel

AmperageProcessShield capShieldNozzle
retaining cap		Nozzle*Swirl ringElectrodeWater tube
170AO2/Air4202001008665942036510087904 (.140) Bore42024210086653420368
300AO2/Air4202001008665942036510086655 (.180) Bore42024210086653420368
460AO2/Air4202001008665942036510086657 (.195) Bore42024210086653420368
Part numberDescription
10083904XPR460 Mild steel consumables starter kit
10083905XPR460 Mild steel consumables starter kit (torch included)

XPR460

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