CUTTING & GOUGING

Gouging operations can be carried out using the following thermal processes:

• Oxy-fuel process

• Plasma arc

• Manual metal arc (MMA)

• Air carbon arc

 Flame or Oxy-fuel Gouging

Flame gouging is a variant of conventional oxy-fuel gas welding. Oxygen and a fuel
gas are used to produce a high temperature flame for melting the steel. When
gouging, the steel is locally heated to a temperature above the 'ignition' temperature
(typically 900°C) and a jet of oxygen is used to melt the metal - a chemical reaction
between pure oxygen and hot metal. This jet is also used to blow away molten metal
and slag. It should be noted that compared with oxy-fuel cutting, slag is not blown
through the material, but remains on the top surface of the work piece. The gouging
nozzle is designed to supply a relatively large volume of oxygen through the
gouging jet. In oxy-fuel gouging, equal quantities of oxygen and acetylene are used
to set a near-neutral preheating flame. The oxygen jet flow rate determines the depth
and width of the gouge.
CONT…
 Plasma Arc Gouging
The use of the plasma arc as a gouging tool dates back to the 1960s when the
process was developed for welding. Compared with the alternative oxy-fuel and
manual metal arc gouging techniques, plasma arc has a needle-like jet which can
produce a very precise groove, suitable for application on almost all ferrous and
non-ferrous materials. Plasma gas can be argon, helium, argon/hydrogen, nitrogen,
or air.
 Manual Metal Arc and Air Carbon Arc Gouging
In these processes an electrical arc is generated to melt the material. Other
techniques like special electrodes or a jet of compressed air are used to blow away
the molten material. No specific high purity or compressed gases are needed in these
processes.
 What is Air Carbon Arc Gouging, how does it work, and what are the advantages
What is Air Carbon Arc Gouging?
Air carbon arc gouging is a process of removing metal by means of heat generated
from a carbon arc. The process uses a carbon/graphite electrode, compressed air and
a standard power source. The intense electric arc used between the tip of a carbon
electrode and a metal work piece cuts and melts the work piece. The arc is initiated
by striking the electrode tip on the surface of the work piece. Then compressed air
is used for blowing the molten metal thoroughly from the metal surface. The metal
is only cut or gouged along the airflow direction. This process is simple to
apply. The main purpose is to remove defective or old welds in order to repair or
dismantle equipment. Manual metal arc (MMA) welding equipment can be used
when air carbon arc gouging however unlike MMA the tip is not withdrawn to
establish length.
 How Does it Work?

A power source with high voltage capacity is required. DC (direct current) is most
suitable and preferred for steel and stainless steel. AC (alternating current) can also
be used however works better for case iron, copper and nickel alloys. The power
source must have a constant current output characteristic otherwise the high voltage
current can cause the electrode tip to “explode” when touched to the piece being
worked on.
A compressed air line, up to 100psi or separate bottled gas supply, around 35psi, are
used. There are no advantages in using higher pressures as they may not remove the
molten metals properly.
The electrode is a graphite-carbon rod with a cooper coating. The cooper coating
reduces electrode erosion. By using the correct electrode diameter required for the
width and depth of the gouge, cutting can be precisely controlled and material waste
is kept to a minimum.
CONT…
 What Are the Advantages?

1- The main advantage of manual metal arc (MMA) gouging is that the same power
source can be used for welding, gouging or cutting, simply by changing the type of
electrode.
2-The air carbon arc cutting process can be performed on the work piece in all
directions.
3-The temperature of the surrounding area of the cut material does not reach the
maximum as the metal is quickly removed after melting.
4-The process can gouge or cut almost all common metals.
5-As most of the surface carbonized materials, near the cut, are removed during a
cleaning process the scraps can be re-melted.