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Oxyfuel Gas Cutting

14. Chapter. Oxyfuel Gas Cutting. Describe the function of each component of an oxyfuel gas cutting outfit. Correctly and safely assemble an oxyfuel gas cutting outfit. Correctly and safely test the cutting outfit for leaks.

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Oxyfuel Gas Cutting

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  1. 14 Chapter Oxyfuel Gas Cutting

  2. Describe the function of each component of an oxyfuel gas cutting outfit. • Correctly and safely assemble an oxyfuel gas cutting outfit. • Correctly and safely test the cutting outfit for leaks. • Describe the difference between a positive-pressure and injector-type cutting torch. • Properly turn on and shut down an oxyacetylene cutting outfit. • Correctly select the proper cutting tip and working pressures for cutting a particular thickness of steel.

  3. Cut base metal using an oxyacetylene cutting torch. • Distinguish between a well cut surface and a poorly cut surface, and be able to adjust where necessary to perform a good cut. • Describe the gouging process and state when it is used. • Pass a test on safe practices and procedures while oxyfuel gas cutting or gouging. • List all the safety equipment that should be worn and used when oxyfuel gas cutting in various positions.

  4. Oxyfuel Gas Cutting • An oxyfuel gas flame is used to heat the metal and an oxygen jet is used to perform the cutting • Oxyfuel gas cutting (OFC) is also called oxygen cutting • Many layers of metal can be cut at the same time (stack cutting) • OFC is useful when shape-cutting metal parts

  5. The Heat of Combustion of Steel • Virtually all materials burn if they are heated to their ignition temperature in the presence of oxygen • During the process of burning, steel releases heat that is measured in British thermal units (Btu) or joules • This is called the heat of combustion

  6. Oxyfuel Gas Cutting Process • A special torch and tip is used in the OFC process • Cutting tips have one or more preheating orifices • Cutting oxygen emits from the central orifice when the welder presses the cutting oxygen lever (Victor, a division of Thermadyne Industries, Inc.)

  7. Oxyfuel Gas Cutting Process • The preheating flames are used to heat a spot on the base metal to its ignition temperature • As the torch is moved along a line, the metal is cut, forming a kerf • The preheating flames are kept burning throughout the entire cutting process

  8. Cutting Outfit • A cutting outfit includes all equipment required to make a cut • A cutting station includes the outfit, lighting, ventilation, a cutting table, and possibly a booth • The cutting torch, which provides an oxygen cutting jet, is quite different from a welding torch

  9. Cutting Torch • The cutting torch is connected to oxygen and fuel gas cylinders • The welder controls the cutting operation using the cutting torch lever (ESAB Welding and Cutting Products)

  10. Cutting Torch • Before the torch is turned on, the desired cutting tip must be inserted into the torch • There are two types of OFC torches • Positive-pressure torches • Injector-type torches

  11. Lighting a Positive-Pressure Oxyacetylene Cutting Torch • Check the condition of all equipment • Inspect the regulators • Open the oxygen valve very slowly • Turn the cylinder valve all the way open • Open the acetylene cylinder valve 1/4 to 1/2 turn

  12. Lighting a Positive-Pressure Oxyacetylene Cutting Torch • Open the torch oxygen valve one full turn • Open the oxygen cutting valve • Adjust the oxygen regulator to give the desired pressure • Open the acetylene torch valve one turn (Uniweld Products, Inc.)

  13. Lighting a Positive-Pressure Oxyacetylene Cutting Torch • Turn in the acetylene regulator adjusting screw until the low-pressure gauge indicates the desired working pressure • Open the torch acetylene valve 1/16 to 1/8 turn before lighting the torch • Adjust the acetylene until most of the smoke clears from the flame • Open the torch oxygen valve and adjust it to obtain neutral preheat flames

  14. Safety • The welder should stand to one side of the gauges when opening the oxygen valve • Leave the acetylene cylinder valve wrench in place so the valve can be turned off quickly • Never use acetylene at above 15 psig (103kPa) • Check the low-pressure gauge readings to make sure that the pressures are not rising • A rising pressure indicates that a valve is leaking • The outfit should be shut down immediately • Use a flint lighter to ignite the acetylene

  15. Lighting an Injector-Type Oxyacetylene Cutting Torch • Several steps are required to turn on the outfit, purge the system, and light the torch • This illustration shows typical gas flow through an injector-type oxyacetylene cutting torch

  16. Lighting an Injector-Type Oxyacetylene Cutting Torch • Check the condition of all equipment • Inspect the regulators • Open the oxygen cylinder valve until the regulator high-pressure gauge reaches its maximum reading • Turn the cylinder valve all the way open • Slowly open the acetylene cylinder valve 1/4 to 1/2 turn • Open the torch oxygen valve 1/4 turn • Open the torch oxygen cutting orifice lever wide open • Adjust the oxygen regulator screw for correct working pressure

  17. Lighting an Injector-Type Oxyacetylene Cutting Torch • Close the torch oxygen valves • Open the torch acetylene valve fully • Adjust the acetylene working pressure • Close the torch acetylene valve • Check the low-pressure gauges • Open the torch oxygen valve 1/4 turn • Open the torch acetylene valve fully • Use a spark lighter to ignite the fuel gas • Press down the oxygen cutting lever and adjust the torch acetylene valve until the preheating flames are neutral

  18. Safety • Leave the wrench in place on the acetylene cylinder valve • Check the low-pressure gauges for any gradual increase in pressures • If the pressures are increasing, the regulator seat may be leaking • If the pressure on either of the low-pressure gauges is increasing, shut down immediately • Use a spark lighter to ignite the fuel gas

  19. Using a Cutting Torch • To cut, bring the tip of the inner cone of the preheating flames to the edge of the metal to be cut • The jet of oxygen coming from the oxygen jet causes the heated metal to burn away, forming the kerf

  20. Using a Cutting Torch • Drag is a measurement made in the direction of travel between the entry and exit points of the cutting jet • The slag stream can lag excessively behind the torch tip travel • Possible causes include • The flame adjustment may be incorrect • The cutting oxygen pressure adjustment may be too low • The tip travel is too fast and the metal is not being preheated enough

  21. Cutting Attachments • The cutting attachment is connected to the welding torch body to change the torch from a welding torch to a cutting torch • For portable kits, the attachment saves space • The operation of the torch with the cutting attachment is the same as the operation of a regular cutting torch

  22. Cutting Attachments • This illustration shows a cutting attachment installed on a torch • The welding torch body has an oxygen valve and a torch acetylene valve • The cutting attachment has a torch oxygen valve and a cutting oxygen lever (CONCOA)

  23. Safety • The torch valves on the welding torch body must be turned off before the cutting attachment is disconnected

  24. Cutting Tips • Cutting tips normally have at least two orifices • One orifice is for the cutting oxygen • One or more small orifices are for preheating the metal to be cut • One-piece tips are used for oxyacetylene cutting only • Two-piece tips are used for all other gas cutting

  25. Cutting Steel with the Oxyfuel Gas Cutting Torch • Metals that can be cut with the oxyfuel gas cutting torch are divided into two classes • Metals whose oxides have a lower melting temperature than the metal itself • Metals whose oxides have a higher melting temperature than the metal itself • Practically all steel falls under the first classification

  26. Cutting Steel with the Oxyfuel Gas Cutting Torch • The second class includes cast iron, some alloy steels, stainless steel, and nonferrous metals • It is very important that refractory oxides be reduced by chemical action or be prevented from forming • If too much oxygen is fed to the steel being cut, this leaves a bell-mouthed kerf on the side of the metal away from the torch

  27. Cutting Steel with the Oxyfuel Gas Cutting Torch • The metal at the bottom of the cut is not burned away if the torch is moved too rapidly • The large drag leaves a kerf that is very rough and irregular in shape

  28. Cutting Steel with the Oxyfuel Gas Cutting Torch • Metal that is very dirty and rusty should be cleaned before starting the cutting operation • In some cases the thickness of the metal requires an oscillating motion in order to obtain the necessary width of a cut • The welder should stand in a comfortable position that permits looking into the cut as it is being formed

  29. Safety • Welders should wear • Safety boots with high tops • Trousers without cuffs • Leggings to protect against flying molten slag • Welding leggings are pieces of leather that cover the shin and top of the shoe • If trousers have cuffs, they must be covered to keep them from catching slag

  30. Cutting Thin Steel • Cutting steel that is 1/8″ or less in thickness requires the use of the smallest cutting tip • A tip with only a few preheat holes is often used • The tip is usually pointed in the direction the torch is traveling • Be careful to keep the end of the preheating inner cone just above the metal

  31. Cutting Thick Steel • Steel over 1/2″ thick should be cut by holding the torch so the tip is perpendicular to the surface of the base metal being cut • A cut is normally started at the edge of the stock

  32. Cutting Thick Steel • The thicker the steel, the greater the time required to raise the temperature of the steel high enough to make clean cuts • To start a cut faster, a welder begins at the corner of the metal by slanting the torch in the direction opposite the direction of travel • One method used to start cuts is to nick the edge of the metal with a cold chisel

  33. Cutting Thick Steel • Another method used to start cuts is to place an iron filler rod under the preheating flames at the edge of a thick plate • Shaping cutting can be done by • Free-hand cutting • Using special attachments or guides • Setting up an automated cutting torch

  34. Safety • Be sure to read and carefully follow all manufacturer’s tables and safety charts prior to attempting a cutting operation for very thick metal

  35. Cutting Chamfers (Bevels) • Thicker pieces of steel must be prepared with a chamfered edge so the weld penetrates the metal • Bevel angles can be cut at the same time the metal is being cut to size and shape

  36. Cutting Chamfers (Bevels) • A chamfer can also be cut as a separate operation • The technique used to cut a bevel is similar to that used to cut thick metal • The torch is held at an acute angle to the base metal • The cut is generally made at an existing edge of the metal

  37. Cutting Pipe or Tubing • When cutting small-diameter pipe, it is best to keep the tip almost tangent to the inner circumference of the pipe • For larger pipes, it is possible to keep the torch tip perpendicular to the pipe surface while cutting (Thermadyne Industries, Inc.)

  38. Cutting Pipe or Tubing • If the pipe is being chamfered, most welders start the cut at the extreme edge of the pipe and cut back to the marked chamfer ring • It is not the diameter of the pipe that determines the size of the cutting torch tip • The thickness of the pipe wall is the controlling factor

  39. Piercing and Cutting Holes • The term pierce means to produce a relatively small hole through a steel plate • A greater amount of heat is required to preheat the surface for piercing than when starting on a edge • For this reason, a larger tip may be needed • It is good practice to outline the hole first, using special chalk

  40. Safety • Until the steel plate is melted through the bottom surface, molten metal is blown upward by the pressure of the cutting oxygen

  41. Cutting and Removing Rivet Heads • Cutting torches are frequently used in salvage operations • Torches are used to remove the two types of rivet heads • Round-head • Countersunk-head • If possible, the welder should do the cutting without damaging the steel plate

  42. Cutting and Removing Rivet Heads • For cutting the round-head rivet, preheat the head of the rivet to a bright cherry red • The steel plate is usually adequately protected from the flame by a coating of scale (oxide) • Countersunk rivet heads can be removed by carefully cutting around the countersunk angle

  43. Gouging with the Cutting Torch • Gouging is a process that removes metal from the surface of a part to a desired depth • For gouging, a lower oxygen cutting pressure and a larger diameter cutting tip orifice are used

  44. Gouging with the Cutting Torch • In a gouging tip, there are five or six preheat orifices to provide even distribution of the preheat flames • The speed of torch movement is important • Moving the torch too rapidly creates a groove that is too narrow and shallow • Moving the torch too slowly creates a gouge that is too deep and wide

  45. Cutting Alloy Steels • Of the alloy steels, stainless steel is the most widely used • Many alloy metals have melting temperatures below that of mild steel • The metal to be cut should be placed so that the cutting tip and flame are in a horizontal position whenever possible

  46. Cutting Alloy Steels • A slight, quick up-and-down motion of the torch facilitates the removal of slag • Like carbon steel, alloy steels must be preheated before the cutting operation is started

  47. Cutting Alloy Steels • Stainless steel must be preheated to a white heat before the cutting oxygen is turned on • When the cutting is often interrupted by unmeltable slag, a welder may hold a mild steel welding rod in the kerf of the metal • Adding welding rod is also useful when cutting poor grade steels, cast irons, and old, oxidized steel castings

  48. Cutting Cast Iron • It is more difficult to cut cast iron than steel • This is because iron oxides of cast iron melt at a higher temperature than the cast iron itself • It is important to preheat the whole casting before starting the cut • Use a carburizing flame to prevent oxides from forming on the surface before cutting starts • The casting should be cooled very slowly if gray cast iron is desired • Rapid cooling creates a white cast iron grain structure

  49. Automatic Cutting • Automatic cutting equipment requires a controller or a computer to control the operation • Feedback controls monitor the automatic cutting process and make needed corrections • In semiautomatic cutting, some changes to the process may be required while cutting is taking place

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