GAS CUTTING
Gas Cutting Set Up
Equipment used are:
• Gas cutting torch.
• Pressure regulators.
• Gas cylinders.
• Hoses and Hose
fittings.
• Non return valve.
• Goggles and glasses.
• Gloves and apron
• Spark lighter and
spanner.
Cutting Torch:
It is used to cut materials.
It is similar to welding torch, but can be identified
by the oxygen blast trigger or lever.
This oxygen reacts with the metal, producing more
heat and forming an oxide which is then blasted
out of the cut.
The cutting torch peripheral flame only heat the
metal to start the process.
Gas Hoses:
A double-hose or twinned design can be used,
meaning that the fuel and oxygen hoses are used
together.
The colour of the hoses varies between countries.
In UK and other countries(except united states),
the oxygen hose is blue (black-old equipment) and
the acetylene(fuel) hose is maroon.
The thread on oxygen hose is right handed and on
fuel hose is left handed just to avoid accidental
miss-connection.
Non-return Valve:
Acetylene is not just flammable but it is explosive
in certain condition.
A Non-return Valve is needed to prevent black
flow of detonation wave created by acetylene
explosion.
So , It should be installed to prevent flame or
oxygen-fuel mixture being pushed back into either
cylinder and damaging the equipment or causing a
cylinder to explode.
Fuels:
Oxy-fuel processes may use a variety of fuel gases,
the most common being acetylene.
Other gases that may be used
are propylene, liquefied petroleum gas (LPG),
propane, natural gas, hydrogen,
and MAPP(Methylacetylene-propadiene) gas.
LPG , Propane, Methane , Butane, Natural gas are
suitable for cutting but not for welding.
Working of Oxy-acetylene Gas
Cutting
A cutting torch has a
60- or 90-degree
angled head with
orifices placed around
a central jet.
The process consists of
preheating the metal
to be cut to its kindling
temperature e.g. 8700 C
for steel.
The preheating is done by oxy-acetylene gas flame,
which is supplied from surrounding openings of
the cutting torch.
When this temperature is attained, a jet of high
pressure oxygen from a central opening of cutting
torch is directed on the red hot metal.
The metal is rapidly oxidized, and slag is formed.
This slag is washed out by the jet of oxygen.
The process of cutting steel consist of following
reaction:
The metal is cut entirely by exothermic chemical
action.
The Iron and Steel itself is not melted because the
rapid rate at which the oxide is produced blows them
away from the cut-zone.
The heat to keep the cut going—once it has started—
is provided partly by the heating jet, and partly by the
heat of the chemical action.
The following two points should be satisfied:
1. The melting point of the metal should be greater
than the oxidation temp. of the metal.
2. The melting point of the formed oxides must be
lower than that of the base metal itself.
Although acetylene is commonly used as a fuel in
this process , other gases can be used including
butane, methane, propane, natural gas.
Types of Flames
1. Oxidizing flame(Excess of Oxygen)
2. Neutral flame or Natural flame (Acetylene
&Oxygen in equal amount)
3. Carburizing or Reducing flame (Excess of
Acetylene)
Oxidizing Flame
It is burnt in excess amount of oxygen with 1.15-1.5
times of acetylene.
It has highest temp amongst all flame at inner
cone of 33000 C – 35000 C.
It produces roaring sound with less smoke.
Material-Copper ,Brass ,Zinc.
The oxidizing flame creates undesirable oxides to
the structural and mechanical detriment of most
metals.
A slightly oxidizing flame is used in braze-welding
and bronze-surfacing while a more strongly
oxidizing flame is used in fusion welding certain
brasses and bronzes.
Neutral Flame
It is the most generally used flame for cutting or
welding.
It is burnt with equal amount of oxygen and
acetylene.
It has flame temp of 31000 C at inner core.
It produces hissing sound with medium smoke.
Material-M.S, C.I, Low carbon Steel, Medium
carbon steel.
The welder uses the neutral flame as the starting
point for all other flame adjustments because it is
so easily defined.
The two parts of this flame are the white inner
cone and the blue outer cone. The inner cone is
where the acetylene and the oxygen combined.
Reducing Flame
It is burnt in less amount of oxygen with 0.85-0.95
times of acetylene.
It has flame temp of 29000 C at inner core.
It has no sound with more smoke.
Material-Nickel alloys, High Carbon steel.
It has secondary luminous cone which is extra in
comparison to other two types , which gives
reducing effect in welding areas.
This flame is characterized by three flame zones;
the hot inner cone, a white-hot "acetylene feather",
and the blue-colored outer cone.
The reducing flame is typically used for hard
facing operations or backhand pipe welding
techniques.
Limitations of Oxy-fuel cutting
Oxy-fuel cutting is not recommended for the cast
iron because its ignition temperature is higher
than its melting temperature.
The process is not appropriate for cutting
stainless-steel, high-alloy chromium, chrome-
nickel alloys, and non-ferrous alloys because
oxides has higher melting point than base metal
itself.
Applications of Oxy-fuel cutting
Oxygen cutting would be useful only for those
materials which readily get oxidized and the oxides
have lower melting points than the metals. So it is
most widely used for ferrous materials.
Oxygen cutting is NOT used for materials like
aluminum, bronze, stainless steel which resist
oxidation.
Cutting of high carbon steels and cast irons require
special attention due to formation of heat affected
zone (HAZ) where structural transformation
occurs.
Safety Precautions
Never move cylinders without protective caps in
place.
Do not wear clothing made of synthetic fibers
while welding.
Before and while lighting the flame, keep the tip
pointed away from your body.
Do not cut on containers that have held flammable
materials.
Set the operating pressure carefully. Never use
acetylene at a pressure over 15 psi.
Store oxygen cylinders away from acetylene
cylinders. A non-combustible wall at least 5 feet
high should be used to separate cylinders.
Be sure the cylinder valves are closed and pressure
is relieved from the hoses before you leave the
work area.
Wear welding gloves, helmet, leather apron,
welding chaps, leather shoes, welding goggles, and
other personal protective equipment to help
prevent weld burns and injury.
THANK YOU
