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15
15.1
Oxy-fuel cutting
Oxy-fuel cutting cuts or removes metal by the chemical reaction of oxygen
with the metal at elevated temperatures. Temperature is provided by a gas
flame which preheats and brings the material up to the burning temperature
(approximately 850oC). Once this is achieved, a stream of oxygen is
released which rapidly oxidises most of the metal and performs the actual
cutting operation. Metal oxides, together with molten metal, are expelled
from the cut by the kinetic energy of the oxygen stream. Moving the torch
across the workpiece produces a continuous cutting action.
Oxygen
Heating flame
Slag jet
Oxy-fuel cutting.
These conditions are fulfilled by carbon steels and some low alloy steels.
However, the oxides of many of the alloying elements in steels, such as
aluminium and chromium have melting points higher than those of iron
oxides. These high melting point oxides (which are refractory in nature!)
may shield the material in the kerf so that fresh iron is not continuously
exposed to the cutting oxygen stream, leading to a decrease of the cutting
speed and ultimately an unstable process. In practice the process is
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Preheating time.
Effect on cutting speed and productivity.
Cost and availability.
Volume of oxygen required per volume of fuel gas to obtain a neutral
flame.
Safety in transporting and handling.
Some of the more common fuel gases used are acetylene, natural gas
(methane), propane, propylene and methylacetylene propadiene (MAPP)
gas.
Fuel gas characteristics and applications
15.1.2
Fuel gas
Main characteristics
Applications
Acetylene
Propane
MAPP
Cutting underwater
Propylene
Methane
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The face of a satisfactory cut has a sharp top edge, drag lines, which are
fine and even, little oxide and a sharp bottom edge. Underside is free of
slag.
A satisfactory cut is shown in the centre. If the cut is too slow (left) the top
edge is melted, there are deep grooves in the lower portion of the face,
scaling is heavy and the bottom edge may be rough, with adherent dross. If
the cut is too fast (right) the appearance is similar, with an irregular cut
edge. Plate thickness 12mm.
With a very fast travel speed the drag lines are coarse and at an angle to
the surface with an excessive amount of slag sticking to the bottom edge of
the plate, due to the oxygen jet trailing with insufficient oxygen reaching the
bottom of the cut.
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A satisfactory cut is shown in the centre. If the preheating flame is too low
(left) the most noticeable effect on the cut edge is deep gouges in the lower
part of the cut face. If the preheating flame is too high (right) the top edge is
melted, the cut irregular and there is an excess of adherent dross. Plate
thickness 12mm.
A satisfactory cut is shown in the centre. If the blowpipe nozzle is too high
above the work (left) excessive melting of the top edge occurs with much
oxide. If the torch travel speed is irregular (right) uneven spacing of the drag
lines can be observed together with an irregular bottom surface and
adherent oxide. Plate thickness 12mm.
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a)
b)
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Advantages
Approximately five times faster than chipping.
Easily controllable, removes defects with precision as they are clearly
visible and may be followed with ease. The depth of cut is easily
regulated and slag does not deflect or hamper the cutting action.
Low equipment cost no gas cylinders or regulators necessary except onsite.
Economical to operate as no oxygen or fuel gas required. The welder
may also do the gouging (no qualification requirements for this
operation).
Easy to operate as the equipment is similar to MMA except the torch and
air supply hose.
Compact with the torch not much larger than an MMA electrode holder,
allowing work in confined areas.
Versatile.
Can be automated.
Disadvantages
Other cutting processes usually produce a better and quicker cut.
Requires a large volume of compressed air.
Increases the carbon content leading to an increase in hardness in of
cast iron and hardenable metals. In stainless steels it can lead to carbide
precipitation and sensitisation so grinding the carbide layer usually
follows arc air gouging.
Introduces hazards such as fire (due to discharge of sparks and molten
metal), fumes, noise and intense light.
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