Internal Training

Quality Control

AIR –ARC GOUGING

Info. Source : Mr. Zeljko Asst.Manager & Engineers
Quality Control Department
Presented By : Mr. Selvan – QC Supervisor

1
  What Is Gouging

• Gouging is the process of removing metal from the surface

by melting the area using heat energy.

2
  Types Of Gouging

1.Carbon air arc gouging

2. Oxy-fuel gouging

3
  Types Of Gouging

1. Carbon air arc gouging

• The carbon air arc Gouging process uses an arc to melt the
metal, which is blown away by a high-velocity jet of
compressed air.

2. Oxy-fuel gouging
• Oxygen and fuel gas are used to produce a high temperature
flame for melting the steel. During gouging the steel is locally
heated above 9000 C and the jet of oxygen will blow away the
molten metal and slag.

4
  Carbon Air Arc Gouging

• Carbon air arc gouging is the process of removing metal by

establishing an arc between carbon rod and metal. Due to
electric arc the metal become molten and a steady flow of air
is blown into molten metal, which removes metal physically.

• The metal removal rate depends upon melting rate and air jet
efficiency. The process is basically “melt and blow” in that
there no exothermic reaction producing extra heat within the
cut zone.

5
Carbon Air Arc Gouging

6
Carbon Air Arc Gouging

7
  Consumable for gouging
• The consumable is a copper coated carbon electrode with the gas
being compressed air.
• The electrodes are rods made from a mixture of graphite and
carbon, and most are coated with a layer of copper to increase
their current carrying capacity

8
 Equipment's used for gouging

9
 Equipment's used for gouging

10
  Power supply requirements for gouging

• A DC power supply with electrode +ve polarity is most suitable.

• AC power source which are also constant current can be used

but with special type AC type electrodes.

• Power source must have a constant current output

characteristic. Other wise work piece will cause a high current
surge sufficient to explode the electrode tip. This will disrupt
the operation and cause carbon pick up.

11
  Where Gouging process is used

Arc-air cutting is the most commonly used method of gouging

and is used extensively for gouging old welds and removing
materials. As carbon air arc gouging does not depends on
oxidation and it can be applied to wide range of metals.

• Removal of surface or internal defects,

• Removal of excess weld metal,
• Removal of root for double sided welding,
• Preparation of bevel edges for welding,
• Gouge out defective metal,
• Remove old or inferior welds,
• Removing cracks in plate.

12
  Qualification to perform gouging

• Trained and well experienced personal can perform gouging.

• Pre-qualification/ approval not required like welder qualification.

13
  Imperfections visible after gouging

• Blow holes,

• Porosity and Cluster porosity,

• Lack of fusion,

• Inclusion,

• Carbon deposit,

• Profile roughness due to poor work man ship.

14
  Check points during inspections after gouging

• Surface must be clean from carbon contaminants.

• Size of the groove(width and depth) to be checked for
suitable access to the root. Profile gauge may be used.
• Gouging Surface profile roughness to be checked.
• In case of any minor defects then that particular area need to
be grind and check for removal of defect.
• For weld repair, after gouging always refer repair map and
ensure that correct depth were gouged.
• Write/mark your comments near by the joint after inspection.

Note-
• Preheat shall be applied prior to gouging as per WPS
• Wire brush cleaning is enough after gouging. Grinding may
be done when required.
15
 Groove size

• Example for insufficient groove made by gouging

causing lack of access to root pass welding.

16
 Profile gauge for inspection

17
  NDT Requirements

• Always refer WPS/Project specification for the requirement of NDT after

gouging. Other wise visual examination is sufficient.

• In case of any repair noticed during NDT, shall be rectified as per WPS
and re NDT shall be carried out.

18
  Quality Control Record

• Record your finding(accepted/not accepted, etc.) in inspection

request form # 436.

19
  Health and Safety
• Smoke, gases, dust and fumes- irritation to eyes/respiratory system.
• Noise - Damage to ear.
• Heat - Skin burn (touching hot piece), injury.
• Flying metal particles/sparks - Arc eye/flash, skin burn, damage to
property.
• Fire and burn - Damage equipment's and skin damage.
• Electric Shock - High risk of fatalities.

Control measures
• Read and follow the risk assements available in Corporate Intranet

DO- RISK- 002

• Use proper personal protective devices like mask, ear plugs, shoes.
• Do not touch the gouged area by bare hand.

20
Please sign the attendance sheet

Thank you
21