What Is Oxy-Fuel Cutting?

Understanding Oxy-Fuel Cutting Technique

what is oxy-fuel cutting?” - It’s a thermal cutting process that uses pure oxygen and fuel
gas to cut through materials, such as plate steel.

Heat from an oxy-fuel cutting torch is used to raise the surface or edge of the steel to
approximately 1800 degrees Fahrenheit. Oxygen is then directed to the heated area using
a fine, high-pressure stream. The steel begins to oxidize and is blown away to form a
cavity. The heat and stream of oxygen move at a consistent speed to cut into the metal.

The actual chemical reaction that takes place during oxy-fuel cutting is sometimes known
as “rapid rusting” or “rapid, controlled rusting.” This is simply because the steel is
rapidly oxidized.

The Metal

Oxy-fuel cutting, also called “burning,” “torch cutting,” or “flame cutting,” is widely
used in many industrial settings, but only on one metal - steel. It can cut all shapes and
sizes of steel in thicknesses from 0.5 mm to 250 mm.

However, only metal with oxides at a lower melting point than the base metal itself can
be cut using the process. This includes low carbon, mild steel and some low alloy steels.
Otherwise, once the metal oxidizes, either a protective crust begins to form or the
material melts and flows away before cutting can take place.

Oxygen
The purity of the oxygen source will not only impact the cutting speed, but also the cut
quality. It should be no less than 99.5% pure.

Nozzle design plays a vital role when it comes to ensuring the air stream remains pure.
For instance, it protects the oxygen jet from air entrainment, which can lead to air
bubbles or air pockets in the metal.

The Gasses

Not all fuel gasses are created equal when it comes to an oxy-fuel cutting system. The
most common are propane, acetylene, propylene, liquified petroleum gas, MAPP
(methylacetylene-propadiene), and natural gas. Depending on the flame temperature and
heat distribution, the type of gas can impact factors like edge quality, pierce time, and
cutting speed.

Here are some factors that may influence why you choose a specific fuel gas:

 Acetylene: Acetylene produces the highest flame temperature of all the fuel gases.
It leads to more rapid piercing. It also produces a more intense flame, reducing the
size of the Heat Affected Zone (HAZ) and the degree of distortion.
 Propane: Propane has a lower flame temperature than acetylene. Piercing is
therefore slower than with acetylene; however, the cutting speed is approximately
the same.
 MAPP: MAPP gas is a mixture of various hydrocarbons, methylacetylene and
propadiene. It is commonly used instead of acetylene because it offers a more
evenly distributed heat source.
 Propylene: Propylene is a liquid petroleum gas product. It has a similar flame
temperature to MAPP and requires an injector torch to achieve optimal heat flow
and cuts. It works by concentrating the heat on the outer edges of the heat cone.
 Natural Gas: Natural gas has the lowest flame temperature when compared to
other gasses. As a result, it has the slowest time for piercing.

Oxy-Fuel Cutting Process

Oxy-fuel cutting is the most cost-efficient process for carbon steel cutting. It can also be
combined with plasma cutting or waterjet cutting on the same part. Here are the basics of
how it works:
Step 1: Preheat

Using preheat flames from an oxy-fuel torch, the steel is heated to its kindling (or
ignition) temperature of approximately 1800 degrees Fahrenheit. It’s then ready to react
with the oxygen.

Inside the torch, fuel gas is blended with oxygen to create a highly flammable mixture. A
nozzle with multiple holes arranged in a circular pattern works to focus the flammable
gas mixture through multiple, small jets. The fuel-oxygen mixture ignites outside the
nozzle and the preheat flames form just outside the nozzle tip.

During the process, the fuel-to-oxygen ratio can be adjusted. This will help to produce the
highest possible temperature in the smallest possible flame. As a result, there’s more
control and the heat can be concentrated in a small area on the steel plate surface.
Step 2: Piercing

Piercing simply means the initial penetration of the surface to be cut. Once the surface or
edge of the plate has reached kindling temperature, an oxygen jet is turned on to begin
piercing through the plate. This is called the “cutting oxygen.”

The jet is formed by a single bore in the center of the nozzle. As the stream of cutting
oxygen hits the pre-heated steel, the rapid oxidation process begins.

The oxidation process is referred to as an exothermic reaction. In other words, it gives off
more heat than it takes to get started. The oxidized steel then forms molten slag, which is
blown away by the jet, enabling it to pierce through the material.

The process of piercing can take a fraction of a second or several seconds, depending on
the thickness of the plate. During this time, the stream of cutting oxygen is working to
push deeper and deeper and penetrate into the plate. As this is happening, the molten slag
is being blown out of the pierce hole.

If performed properly, it leads to a small puddle of slag on top of the plate. However, a
sloppy approach can produce a large geyser of molten steel.
Step 3: Cutting

Once the cutting oxygen stream has made its way through the plate, the torch can begin
to move at a constant speed. This forms a continuous cut. The cutting tip and the gas
flows set on the regulators control the thickness of the metal being cut.

To keep the exothermic reaction working, the torch keeps the steel heated, just in front of
the cut, throughout the process. The heat applied to the plate is therefore continuous,
allowing the torch to continue to move forward. At the same time, the molten slag is
blown out of the bottom of the plate.

While these are the basic steps of the process, there are many other factors that play a
part. These include the speed, cut oxygen pressure, preheat flame adjustment, cutting
height, and plate temperature. Each of these can impact the final quality of the cut edge
and determine the successfulness of your oxy-fuel cutting operation.
What is Oxy-Acetylene Welding?
Oxy-acetylene welding, also known as oxy fuel welding, gas welding or blowpipe welding, is
a time-honored technique that is commonly used to join metals for repair work or creative
projects.

How oxy-acetylene welding works

Oxy-acetylene welding is a type of gas welding that involves heating parts with a torch and
joining them together with or without a suitable filler metal.
Oxy-acetylene welding creates a strong, durable bond. There are several different oxy-fuel
welding methods, each suited to specific applications.

Autogenous welding
Autogenous welding is used to weld two parts made of the same metal, which therefore
share the same melting point. Both parts are heated until they melt and bond, without the
use of filler metal. To achieve a successful weld, it is essential to reach the melting point
quickly without overheating the parts, to preserve their natural properties.
Soft soldering
Soft soldering uses tin wire as a filler metal, which has a melting point below 400°C. This
technique is ideal for domestic repairs, electronics, electrical work and more. Soft soldering
prevents oxidation and delivers a quality finish. Soft soldering involves heating the parts,
applying the tin wire and allowing the assembly to cool. It creates a precise, strong solder
joint.

Hard soldering (Silver soldering)

Hard soldering is similar to soft soldering, but uses a filler metal with a higher melting point
(reaching up to 700°C) such as copper or silver. This process is used widely in the plumbing
and heating industries. Positioning the parts is crucial to achieving a strong, high-quality
weld. The process involves continuously applying the torch to the weld line while feeding
the filler metal into the weld area.

Brazing
Brazing relies on an even higher soldering temperature, above 900°C. The preferred filler
metal is coated brass. This method is ideally suited to larger-scale jobs. The process is
similar to that of hard soldering but it results in stronger bonds.

Steps in oxy-acetylene welding

Oxy-acetylene welding must be performed following a well-defined, step-by-step process, to
ensure a successful weld. Here are the main steps in ocy-acetylene welding:

1. Prepare the parts

The first step is to prepare the parts that will be joined. This involves carefully cleaning the
surfaces of the metals and removing any traces of dirt, oil or paint. Thorough scrubbing with
an abrasive will also create microgrooves that help the filler metal stick to the surface.

2. Select a torch and adjust the flame

Choosing the right torch for the welding method and metal type is just as important as the
other steps in this process. Depending on the requirements of your welding project, you can
choose between a low-pressure or injector type torch, and an equal pressure torch. Before
beginning to weld, make sure the flame is properly adjusted so that you can control the
temperature and make a proper weld.

3. Lighting the torch

Once you have chosen a torch an opened the gas supply, it’s time to light it. Depending on
the type of torch used, there are different ways to do this. For low pressure torches, you will
need to open a valve to let the gas flow out. Equal pressure torches require both gases to
be ignited using a torch striker and not a match.
4. Heating the parts
This stage involves heating the parts you want to weld to the appropriate melting
temperature. Aim the torch at the areas to be welded, and apply heat evenly to avoid
distorting or overheating the parts. It is important to maintain the correct distance and angle
between the torch and the parts. If you need a professional who can perform high-quality
welding, contact us today!
5. Filler metal input
For brazing and soldering methods, the filler metal is added when the parts are hot enough
to melt the material being used: tin, copper or silver wire. The filler is placed between the
two parts to be welded. Capillary action allows it to penetrate the gaps and form the weld.
For autogenous welding, no additional metal is required, as the original metals fuse together
directly.

6. Cooling and finishing

Once the weld is complete, move the torch away from the parts and allow them to cool at
room temperature. To avoid burns, never handle the parts while they are still hot. After the
parts are cool, you can apply finishing touches and achieve a clean, attractive finish using a
wire brush or abrasive.

514 422-8282
Benefits of oxy-acetylene welding
Oxy-acetylene welding offers a number of advantages, which is why it remains so popular
with professional welders. Here are some of the main advantages of this technique:

Versatility
Oxy-acetylene welding offers great versatility, as it can be used on a variety of metals such
as steel, aluminum, copper, brass and many others. This adaptability makes it an ideal
solution for different applications and welding jobs. Whether for industrial machinery
design, artistic projects or more, oxy-acetylene welding can be adapted to a multitude of
materials.
Ease of use
One of the great strengths of torch welding is its ease of use. Even beginners can master
this welding technique with a little practice and training. Thanks to simple flame and gas
flow settings, you can learn to use a torch quickly and easily, and use it to make quality
welds. This accessibility makes it a popular choice for DIY enthusiasts who want to do
welding jobs at home without any in-depth expertise.

Please note: don’t take any risks! If you aren’t sure you have what it takes to carry
out this type of work, contact our experts anytime!
Affordability
Compared with other more complex and expensive welding methods, torch welding is quite
affordable. Torches can be purchased at reasonable prices, making them an economical
option for occasional welding jobs or for people who are new to welding. Maintenance and
consumables costs are also relatively low, making them an affordable solution for many
projects.

Handling
Torches are lightweight, compact tools that are easy to handle and transport. They are an
ideal choice for welding work in confined spaces or outdoors, where it may be harder to use
bulkier welding methods.

Limits of oxy-acetylene welding

Despite its many advantages, oxy-acetylene welding also has a few limitations. It might not
be the right welding technique to use in some situations, for the following reasons:

Lack of precision
One of the main limitations of torch welding is that this method lacks precision. Compared
with other welding techniques like TIG welding (GTAW) or MIG/MAG welding, torch
welding may not be precise enough, particularly for doing soldering work on sensitive
electronic components.
Variable weld quality
The quality of a torch weld can vary according to the experience and skill of the welder.
Obtaining uniform weld quality requires good technique and an in-depth knowledge of torch
handling. Beginner welders may find it difficult to achieve consistent, strong welds. Weld
quality can also be influenced by flame settings, metal feed rate and the cleanliness of the
welding surface.
Limited welding capability
Although versatile, torch welding may not be suitable for complex or large-scale welding
tasks. Other specialised techniques will likely be required for jobs that demand extreme
precision, high-quality welds or sophisticated assemblies.

HARtech: your partner for industrial projects

Oxy-acetylene welding is a versatile and accessible technique that offers many advantages
to both private and professional users. It is easy to learn and affordable, making it a reliable
choice for everything from home repairs to assembling complex industrial parts.
References: https://esab.com/us/nam_en/esab-university/articles/what-is-oxy-fuel-cutting/?
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