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Thermal Cutting Processes

cutting

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956 views18 pages

Thermal Cutting Processes

cutting

Uploaded by

Lương Hồ Vũ
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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CSWIP 3.

1 Welding Inspection

Cutting Processes

TWI Training & Examination Services

Copyright © TWI Ltd 2008


Course Reference WIS 5
Course notes section reference 15
Oxyfuel Gas Cutting Process
A jet of pure oxygen reacts with iron, that has been preheated to
its ignition point, to produce the oxide Fe3O4 by exothermic
reaction.This oxide is then blown through the material by the
velocity of the oxygen stream

Different types of fuel gases may be used for the pre-heating


flame in oxy fuel gas cutting: i.e. acetylene, hydrogen,
propane. etc

By adding iron powder to the flame we are able to cut most

Copyright © TWI Ltd 2008


metals - “Iron Powder Injection”

The high intensity of heat and rapid cooling will cause


hardening in low alloy and medium/high C steels  they are
thus pre-heated to avoid the hardening effect
Oxyfuel Gas Cutting Process

The cutting torch

Copyright © TWI Ltd 2008


Neutral cutting flame

Neutral cutting flame with


oxygen cutting stream
Oxyfuel gas cutting equipment
Cutting tip

Torch-mix cutting Tip nut


Torch head

torch Mixed
preheat
Cutting oxygen

gases

•fuel and oxygen for Universal


pressure
mixer
preheat flame are mixed
within the torch
•can be injector type (for

Copyright © TWI Ltd 2008


Handle

pressure less than 14 Cutting


oxygen
kPa) or medium lever
Preheat
pressure type Preheat
fuel gas
oxygen
valve
valve
Oxygen
Fuel gas inlet
inlet
Oxyfuel gas cutting equipment
Tip nut
Tip mix cutting
torch Tip mix

Three tube
design

•fuel and oxygen


Preheat
for preheat flames fuel gas
Preheat
Cutting
oxygen
are mixed in the oxygen

tip of the torch

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Cutting
oxygen
lever
Handle

Preheat
valves
Oxyfuel gas cutting related terms

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Oxyfuel gas cutting quality
• Good cut - sharp top edge, fine and even drag lines,
little oxide and a sharp bottom edge

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• Cut too fast -
• Cut too slow - top edge is melted, pronounced break in the
deep groves in the lower portion, drag line, irregular cut
heavy scaling, rough bottom edge edge
Oxyfuel gas cutting quality
• Good cut - sharp top edge, fine and even drag lines,
little oxide and a sharp bottom edge

Copyright © TWI Ltd 2008


• Preheat flame too low - deep • Preheat flame too high - top
groves in the lower part of the cut edge is melted, irregular cut,
face excess of adherent dross
Oxyfuel gas cutting quality
• Good cut - sharp top edge, fine and even drag lines,
little oxide and a sharp bottom edge

Copyright © TWI Ltd 2008


• Nozzle is too high above the
works - excessive melting of the • Irregular travel speed - uneven space
top edge, much oxide between drag lines, irregular bottom
with adherent oxide
Mechanised oxyfuel cutting

• can use portable carriages or gantry type machines


 high productivity
• accurate cutting for complicate shapes

Copyright © TWI Ltd 2008


Mechanised oxyfuel cutting

Cutting and bevelling


head

Copyright © TWI Ltd 2008


OFW/C advantages/disadvantages
Advantages: Disadvantages:

1) No need for power supply 1) High skill factor


 portable
2) Wide HAZ
2) Versatile: preheat,
brazing, surfacing, repair, 3) Safety issues
straightening 4) Slow process

Copyright © TWI Ltd 2008


3) Low equipment cost 5) Limited range of
consumables
4) Can cut carbon and low
alloy steels 6) Not suitable for reactive &
refractory metals
5) Good on thin materials
Plasma cutting

Copyright © TWI Ltd 2008


Plasma cutting

•no need to promote


oxidation no preheat
•works by melting and blowing
and/or vaporisation
•gases: air, Ar, N2, O2, mix of Ar
+ H2, N2 + H2
•air plasma promotes
oxidation  increased speed
but special electrodes need

Copyright © TWI Ltd 2008


•shielding gas - optional
•applications: stainless steels,
aluminium and thin sheet
carbon steel
Plasma arc modes

• used for cutting and


joining non-conductive
workpiece
• workpiece is not in the
arc circuit
• heat is obtained from

Copyright © TWI Ltd 2008


plasma jet only
• low energy
concentration
Plasma cutting

Copyright © TWI Ltd 2008


Arc Air Gouging

Copyright © TWI Ltd 2008


Arc-air gouging features
• Operate ONLY on DCEP
• Special gouging copper
coated carbon electrode
• Can be used on carbon
and low alloy steels,
austenitic stainless steels
and non-ferrous materials
• Requires CLEAN/DRY
compressed air supply

Copyright © TWI Ltd 2008


• Provides fast rate of metal removal
• Can remove complex shape defects
• After gouging, grinding of carbured layer is mandatory
• Gouging doesn’t require a qualified welder!

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