Thermal Cutting Processes
• Cutting of metals based on thermal energy
– severing the metal using very high local temperatures.
• The temperature employed is hot enough to remove metal by fusion or
vaporisation.
• Due to the high temperatures, the process causes physical and
metallurgical degradation to the newly formed surfaces.
– Resurfacing of the cut surface is at times required.
Flame Cutting (Oxy-fuel Cutting)
Process is based on two separate chemical reactions occurring in parallel:
• 1st process is combusting a fuel gas with oxygen to raise the temperature
of the cutting region of the metal.
• Same chemical process as for oxy-fuel welding
• 2nd process involves using oxygen to rapidly oxidise the base metal.
• exothermic reaction liberates the majority of the heat.
• Fe + O -> FeO + Heat 1st reaction
• 3Fe + 2O2 -> Fe3O4 + Heat 2nd reaction
• 2Fe + 1.5O2 -> Fe2O3 + Heat 3rd reaction
• 1st 2 reactions dominate, 3rd only occurs in deep section cuts.
How the cutting torch process work:
Cutting torch provides the oxygen and fuel.
• Cutting torch also supplies a uniform stream of high purity oxygen
(known as cutting oxygen)
• The torch mixes the fuel and the oxygen in correct proportions to
produce a preheating flame, directed onto the workpiece.
• Flame cone is kept approx. 1.5 to 3 mm above the surface of material to
be cut.
• The combustion process raises the metal temperature to around 900°C.
• A thin jet of high purity
oxygen is then directed or
shot at this heated spot.
• The iron and oxygen
quickly combine to form
iron oxide which releases
additional heat. 1. 2. 6. Supply tubes
3. Cutting oxygen valve lever
• The oxygen jet also blows 4. 5. Valves
the reaction products from 7. Cutting oxygen orifice
the joint, penetrating 8. Preheat orifices
through the metal.
• The cutting action is self- regulating, provided the (cutting) oxygen jet
and pre-heating flame is maintained.
• Cutting torch moves progressively forward, cutting a narrow slot (kerf)
along the desired line.
• Preheat flame provides a protective shield between the cutting oxygen
stream and the atmosphere.
• In actual practice, the top surface of the material is frequently covered
with scale or rust.
• Must be melted away by the preheating flame to expose a clean metal
surface to the oxygen jet.
Metals that can and can’t be cut with Oxy-fuel Cutting techniques
• Metal that can be cut • Metals that cannot be cut
• Plain Carbon Steel • Stainless Steel
• Low Alloy Steel • Aluminium
• Manganese Steel • Non-ferrous metals
• Low content Chrome Steel •
Use the following link: https://www.youtube.com/watch?v=sEz2Z7f5zv4 to
see a video on oxy fuel cutting.
Arc Cutting Processes
Melting a localized area with a constricted arc, then using a focussed, high
velocity jet of hot, ionized gas to displace the molten metal.
Plasma Arc Cutting
• Plasma – a superheated electrically ionised gas.
• Temperature is in the range 10,000C to 14,000C.
• Arc is formed between the tungsten electrode in the torch and the
workpiece (anode).
• The plasma gas used is usually Nitriogen, Argon or Hydrogen.
How does the Plasma arc process work?
• A pilot arc is used to start the arc process within the torch.
• Ionized gas from the pilot arc is blown through a constricting nozzle
orifice onto the workpiece .
• Forms a low resistance path to ignite the main arc between the
electrode and the workpiece.
• A high-frequency electric arc is established - passed through a stream of
inert gas which is ionized.
• Both the ionized gas and the arc are forced through a small orifice in the
torch nozzle.
• Narrow diameter nozzle increases arc density, plasma temperature and
velocity. (very high velocity)
• This is focussed onto the workpiece.
• High temperatures melt the workpiece metal.
• High velocity plasma blows away the molten metal to form the kerf.
• Secondary gases or water are used to surround and confine the plasma
arc and clean up the formed kerf.
• Feed rates of 200mm/s for aluminium (6mm) and 85 mm/s for steel
(6mm) are possible.
Advantages
• Cuts carbon steel up to 10 times faster than oxy-fuel cutting,
• More economical than oxy-fuel cutting.
• Leaves a narrower kerf.
• Can cut any metal.
• Arc plasma torches provide the highest temperature available.
Disadvantages
• High initial cost of the equipment
Visit: https://www.youtube.com/watch?v=Tcn9gKDUdOE to see a video on
plasma cutting
Air Carbon Arc Cutting
• Similar to Plasma cutting, but the heat is produced by the arc between a
carbon electrode in the torch and the workpiece.
• High velocity air jet is used to blow away the molten metal.
• Electrode is slowly consumed.
• Arc is unrestricted.
• Can be used on a variety of metals, aluminium and non ferrous metals.
• Care needs to be taken against the spattering molten metal.
