Chip-based vs. Thermal Machining: What’s the Difference and When Should You Use Each?

1) Technology Principle

Chip-based machining removes material mechanically and does not introduce heat into the workpiece.
Thermal cutting melts or evaporates the material, creating a Heat-Affected Zone (HAZ) that can change the structure or hardness of the edge.

This difference has a direct impact on the final weld quality.

2) Edge Quality and Accuracy

Chip-based machining

• highest edge quality,
• no slag, no burrs,
• no metallurgical changes,
• accurate and repeatable bevel angles even on thick plates.

Thermal technologies

• laser – clean cut but bevel angle less precise,
• plasma – common root-side dross formation,
• oxy-fuel – largest HAZ, lowest accuracy, requires post-processing.

However, there are situations where the standard setup simply isn’t enough. A typical example is the offset J-bevel – a special variation where the bevel is shifted relative to the plate edge.

Thanks to our ability to provide custom machine configurations, we can adapt the equipment to match exact requirements for angle, depth, and offset. This ensures:

• Perfect match to the technical drawing, essential for high-quality welding

• High accuracy even with complex profiles

• Compatibility with a wide range of materials, including stainless steel and high-strength alloys

Bevels prepared in this way ensure that subsequent welding is faster, more consistent, and requires less filler material.

3) Heat-Affected Zone (HAZ)

• Chip-based machining: zero HAZ → no distortion, no residual stresses, no negative impact on weldability.
• Thermal cutting: HAZ ranges from 0.1 mm (laser) to 5 mm or more (oxy-fuel), which may worsen weldability or require additional edge treatment.

4) Processing Speed

• Chip-based machining: typically 0.5–2.5 m/min depending on machine type.
• Laser / plasma: significantly faster (up to 10–15 m/min).
• Oxy-fuel: slowest.

However, thermal methods almost always require cleaning and correcting the edge, which dramatically increases actual processing time and cost.

5) Costs and Best Applications

Chip-based machining
• higher initial equipment cost,
• saves significant time in welding – the edge is ready immediately,
• ideal for carbon steel, stainless steel, Duplex, Hardox, Inconel, Domex,
• the most stable and reliable method for producing precise weld bevels.

Thermal cutting
• excellent for shapes and contours,
• less suitable for precise weld bevel preparation,
• typically requires additional finishing.

Conclusion

If you need a precise, clean bevel with no thermal influence,
chip-based machining is the clear winner.

If your goal is fast cutting of shapes and contours, laser or plasma is a logical choice — but not a substitute for accurate weld bevel preparation.