What Is Oxy-Fuel Cutting?

Understanding Oxy-Fuel Cutting Technique

what is oxy-fuel cutting?” - It’s a thermal cutting process that uses pure oxygen
and fuel gas to cut through materials, such as plate steel.

Heat from an oxy-fuel cutting torch is used to raise the surface or edge of the
steel to approximately 1800 degrees Fahrenheit. Oxygen is then directed to the
heated area using a fine, high-pressure stream. The steel begins to oxidize and is
blown away to form a cavity. The heat and stream of oxygen move at a
consistent speed to cut into the metal.

The actual chemical reaction that takes place during oxy-fuel cutting is
sometimes known as “rapid rusting” or “rapid, controlled rusting.” This is simply
because the steel is rapidly oxidized.

Oxyacetylene welding, commonly referred to as gas welding, is a process which

relies on combustion of oxygen and acetylene. When mixed together in correct
proportions within a hand-held torch or blowpipe, a relatively hot flame is
produced with a temperature of about 3,200 deg.C. The chemical action of the
oxyacetylene flame can be adjusted by changing the ratio of the volume of oxygen
to acetylene.

Acetylene

This is the primary fuel for oxy-fuel welding and cutting. It is chemically very unstable, and
is stored in special cylinders designed to keep the gas dissolved. The cylinders are packed
with a porous material and then saturated with acetone. When the acetylene is added to
the cylinder, it dissolves; in this solution, it becomes stable. Pure acetylene stored in a free
state explodes from a slight shock at 29.4 pounds per square inch (psi). The acetylene
pressure gauge should never be set higher than 15 psi for welding or cutting.
Oxygen

Oxygen is a colorless, odorless, and nonflammable gas. It is used in the welding process to
increase the combustion rate which increases the flame temperature of flammable gas.

Brazing
Brazing relies on an even higher soldering temperature, above 900°C. The preferred filler
metal is coated brass. This method is ideally suited to larger-scale jobs. The process is
similar to that of hard soldering but it results in stronger bonds.

Autogenous welding
Autogenous welding is used to weld two parts made of the same metal, which therefore
share the same melting point. Both parts are heated until they melt and bond, without the
use of filler metal. To achieve a successful weld, it is essential to reach the melting point
quickly without overheating the parts, to preserve their natural properties.

How Does Oxy Acetylene Welding Work?

Oxy acetylene welding uses a high-heat, high-temperature flame that is

produced by burning a fuel gas (most commonly acetylene) mixed with pure
oxygen. The base material is melted with the filler rod using a flame from
the combination of oxy fuel gas through the tip of the welding torch
(commonly called oxy acetylene torch welding).
The fuel gas and oxygen gas are stored in pressurized steel cylinders.
Regulators in the cylinder reduce gas pressure.
Gas flows through flexible hoses, with the welder controlling the flow via the
torch. The filler rod is then melted with the base material. However, melting
two pieces of metals is also possible without the need of the filler rod.
11.6.1 Positive-Pressure Welding Torches
In a positive-pressure torch, oxygen and fuel gas are mixed in the torch and are burned at the
end of the torch tip. The torch consists of four main parts, as shown in Figure 11-42.
o Body.
o Hand torch valves.
o Mixing chamber.
o Tip.

The design of positive-pressure torches requires that oxygen and fuel gas be supplied under
enough pressure to force them into the mixing chamber, as shown in Figure 11-43. This means
that positive-pressure torches require cylinder or manifold gas supplies, and cannot be used
with low-pressure gas generators. The torch shown in Figure 11-44 has been cut away to show
the mixing chamber and gas passages. Torches are made of various materials, including brass,
aluminum, and/or stainless steel. The various parts are threaded and silver-brazed together.

The hand valves are located either at the end of the torch where the hoses attach to the torch
body, as shown in Figure 11-40, or at the tip end of the torch body as shown in Figure 11-45. The
torch valves are generally either a needle-and-seat or ball-and-seat design, as shown in Figure
11-46. Hand valves are used chiefly for shutting off the gas and turning it on; however, many
welders use them to throttle(make the final flow adjustment to) the gases being fed to the
torch.

Types of Brazing Rods:

Brazing Rods are available in both ferrous and non-ferrous process for
joining/welding different base materials.

1. Aluminium
2. Copper & its alloys
3. Silver Brazing Alloys
4. Steel

Welding Gases

Acetylene
This is the primary fuel for oxy-fuel welding and cutting. It is chemically very unstable, and
is stored in special cylinders designed to keep the gas dissolved. The cylinders are packed
with a porous material and then saturated with acetone. When the acetylene is added to
the cylinder, it dissolves; in this solution, it becomes stable. Pure acetylene stored in a free
state explodes from a slight shock at 29.4 pounds per square inch (psi). The acetylene
pressure gauge should never be set higher than 15 psi for welding or cutting.

Argon
Argon is a colorless, odorless, tasteless, and non-toxic inert gas. Inert gas cannot combine
with other elements. It has a very low chemical reactivity and low thermal conductivity. It
is used as a gas shield for the electrode in MIG, TIG, and plasma welding equipment.

Helium
Helium is a colorless, odorless, tasteless, and non-toxic inert gas. Its boiling and melting
points are the lowest of the elements and it normally exists only in gas form. It is used as a
protective gas shield for many industrial uses including electric arc welding.

Hydrogen

Hydrogen is a colorless, odorless, tasteless, and highly flammable gas. It can be used at a
higher pressure than acetylene and is used for underwater welding and cutting. It also can
be used for aluminum welding using the oxy-hydrogen process.
Oxygen

Oxygen is a colorless, odorless, and nonflammable gas. It is used in the welding process to
increase the combustion rate which increases the flame temperature of flammable gas.
Three distinct flame settings are used, neutral, oxidising and carburising.

Neutral flame

Oxidising flame

Carburising flame
How oxy-acetylene welding works
Oxy-acetylene welding is a type of gas welding that involves heating parts with a torch and
joining them together with or without a suitable filler metal.
Oxy-acetylene welding creates a strong, durable bond. There are several different oxy-fuel
welding methods, each suited to specific applications.

Autogenous welding
Autogenous welding is used to weld two parts made of the same metal, which therefore
share the same melting point. Both parts are heated until they melt and bond, without the
use of filler metal. To achieve a successful weld, it is essential to reach the melting point
quickly without overheating the parts, to preserve their natural properties.

Soft soldering
Soft soldering uses tin wire as a filler metal, which has a melting point below 400°C. This
technique is ideal for domestic repairs, electronics, electrical work and more. Soft soldering
prevents oxidation and delivers a quality finish. Soft soldering involves heating the parts,
applying the tin wire and allowing the assembly to cool. It creates a precise, strong solder
joint.

Hard soldering (Silver soldering)

Hard soldering is similar to soft soldering, but uses a filler metal with a higher melting point
(reaching up to 700°C) such as copper or silver. This process is used widely in the
plumbing and heating industries. Positioning the parts is crucial to achieving a strong, high-
quality weld. The process involves continuously applying the torch to the weld line while
feeding the filler metal into the weld area.

Brazing
Brazing relies on an even higher soldering temperature, above 900°C. The preferred filler
metal is coated brass. This method is ideally suited to larger-scale jobs. The process is
similar to that of hard soldering but it results in stronger bonds.
The Metal

Oxy-fuel cutting, also called “burning,” “torch cutting,” or “flame cutting,” is widely
used in many industrial settings, but only on one metal - steel. It can cut all
shapes and sizes of steel in thicknesses from 0.5 mm to 250 mm.

However, only metal with oxides at a lower melting point than the base metal
itself can be cut using the process. This includes low carbon, mild steel and
some low alloy steels. Otherwise, once the metal oxidizes, either a protective
crust begins to form or the material melts and flows away before cutting can
take place.
Step 1: Preheat

Using preheat flames from an oxy-fuel torch, the steel is heated to its kindling (or
ignition) temperature of approximately 1800 degrees Fahrenheit. It’s then ready
to react with the oxygen.

Inside the torch, fuel gas is blended with oxygen to create a highly flammable
mixture. A nozzle with multiple holes arranged in a circular pattern works to
focus the flammable gas mixture through multiple, small jets. The fuel-oxygen
mixture ignites outside the nozzle and the preheat flames form just outside the
nozzle tip.

During the process, the fuel-to-oxygen ratio can be adjusted. This will help to
produce the highest possible temperature in the smallest possible flame. As a
result, there’s more control and the heat can be concentrated in a small area on
the steel plate surface.

Step 2: Piercing

Piercing simply means the initial penetration of the surface to be cut. Once the
surface or edge of the plate has reached kindling temperature, an oxygen jet is
turned on to begin piercing through the plate. This is called the “cutting oxygen.”

The jet is formed by a single bore in the center of the nozzle. As the stream of
cutting oxygen hits the pre-heated steel, the rapid oxidation process begins.

The oxidation process is referred to as an exothermic reaction. In other words, it

gives off more heat than it takes to get started. The oxidized steel then forms
molten slag, which is blown away by the jet, enabling it to pierce through the
material.

The process of piercing can take a fraction of a second or several seconds,

depending on the thickness of the plate. During this time, the stream of cutting
oxygen is working to push deeper and deeper and penetrate into the plate. As
this is happening, the molten slag is being blown out of the pierce hole.

If performed properly, it leads to a small puddle of slag on top of the plate.

However, a sloppy approach can produce a large geyser of molten steel.

Step 3: Cutting
Once the cutting oxygen stream has made its way through the plate, the torch
can begin to move at a constant speed. This forms a continuous cut. The cutting
tip and the gas flows set on the regulators control the thickness of the metal
being cut.

To keep the exothermic reaction working, the torch keeps the steel heated, just in
front of the cut, throughout the process. The heat applied to the plate is therefore
continuous, allowing the torch to continue to move forward. At the same time,
the molten slag is blown out of the bottom of the plate.

While these are the basic steps of the process, there are many other factors that
play a part. These include the speed, cut oxygen pressure, preheat flame
adjustment, cutting height, and plate temperature. Each of these can impact the
final quality of the cut edge and determine the successfulness of your oxy-fuel
cutting operation.
Steps in oxy-acetylene welding
Oxy-acetylene welding must be performed following a well-defined, step-by-step process, to ensure a
successful weld. Here are the main steps in ocy-acetylene welding:

1. Prepare the parts

The first step is to prepare the parts that will be joined. This involves carefully cleaning the surfaces of the
metals and removing any traces of dirt, oil or paint. Thorough scrubbing with an abrasive will also create
microgrooves that help the filler metal stick to the surface.

2. Select a torch and adjust the flame

Choosing the right torch for the welding method and metal type is just as important as the other steps in
this process. Depending on the requirements of your welding project, you can choose between a low-
pressure or injector type torch, and an equal pressure torch. Before beginning to weld, make sure the
flame is properly adjusted so that you can control the temperature and make a proper weld.

3. Lighting the torch

Once you have chosen a torch an opened the gas supply, it’s time to light it. Depending on the type of
torch used, there are different ways to do this. For low pressure torches, you will need to open a valve to
let the gas flow out. Equal pressure torches require both gases to be ignited using a torch striker and not
a match.

4. Heating the parts

This stage involves heating the parts you want to weld to the appropriate melting temperature. Aim the
torch at the areas to be welded, and apply heat evenly to avoid distorting or overheating the parts. It is
important to maintain the correct distance and angle between the torch and the parts. If you need a
professional who can perform high-quality welding, contact us today!
5. Filler metal input
For brazing and soldering methods, the filler metal is added when the parts are hot enough to melt the
material being used: tin, copper or silver wire. The filler is placed between the two parts to be welded.
Capillary action allows it to penetrate the gaps and form the weld. For autogenous welding, no additional
metal is required, as the original metals fuse together directly.

6. Cooling and finishing

Once the weld is complete, move the torch away from the parts and allow them to cool at room
temperature. To avoid burns, never handle the parts while they are still hot. After the parts are cool, you
can apply finishing touches and achieve a clean, attractive finish using a wire brush or abrasive.

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 BRAZING PROCESS

1. Clean all the joining areas with sandpaper.

2. Use a slight oxidizing flame for brazing and adjust as
needed.
3. Heat edges to a dull red, ensuring equal heating on
both ends. Melt flux-coated rod and ensure tinning on
the area to be brazed.
4. Avoid melting the base metal; prevent overheating.
5. Add filler rod until desired size and shape are
achieved.
6. Allow joint to cool, then remove flux residue with a
wire brush or acid solution followed by rinsing with
water.