Soldadura Arcair

Issue Date: March 2006

Air Carbon-ArcGuide

Version: 1 Form No. 89-250-008

March 2006

Air Carbon-Arc Guide

�

WE APPRECIATE YOUR BUSINESS!

Congratulat�ons on your new Arca�r® product. We are proud to have you as our customer and w�ll str�ve to prov�de you w�th the best serv�ce and rel�ab�l�ty �n the �ndustry. Th�s product �s backed by our extens�ve warranty and world-w�de serv�ce network. To locate your nearest d�str�butor or serv�ce agency call 800-231-9353, or v�s�t us on the web at www.thermadyne.com.

Th�s Operat�ng Manual has been des�gned to �nstruct you on the correct use and operat�on of your Arca�r® product. Your sat�sfact�on w�th th�s product and �ts safe operat�on �s our ult�mate concern. Therefore please take the t�me to read the ent�re manual, espec�ally the Safety Precaut�ons. They w�ll help you to avo�d potent�al hazards that may ex�st when work�ng w�th th�s product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide. Arca�r® �s a Global Brand of Arc Weld�ng Products for Thermadyne Industr�es Inc. We manufacture and supply to major weld�ng �ndustry sectors worldw�de �nclud�ng; Manufactur�ng, Construct�on, M�n�ng, Automot�ve, Aerospace, Eng�neer�ng, Rural and DIY/Hobby�st.

We d�st�ngu�sh ourselves from our compet�t�on through market-lead�ng, dependable products that have stood the test of t�me. We pr�de ourselves on techn�cal �nnovat�on, compet�t�ve pr�ces, excellent del�very, super�or customer serv�ce and techn�cal support, together w�th excellence �n sales and market�ng expert�se.

Above all, we are comm�tted to develop technolog�cally advanced products to ach�eve a safer work�ng env�ronment w�th�n the weld�ng �ndustry.


�� March 2006

!!

WARNINGS

Read and understand th�s ent�re Gu�de and your employer’s safety pract�ces before �nstall�ng, operat�ng, or serv�c�ng the equ�pment. Wh�le the �nformat�on conta�ned �n th�s Gu�de represents the Manufacturer’s best judgement, the Manufacturer assumes no l�ab�l�ty for �ts use.

A�r Carbon-Arc Gu�de Form Number 89-250-008:

Publ�shed by:Thermadyne Industr�es, Inc.2800 A�rport RoadDenton, Texas 76207(800) 231-9353www.thermadyne.com

Copyr�ght © 2006 by Thermadyne Industr�es, Inc.® All r�ghts reserved.

Reproduct�on of th�s work, �n whole or �n part, w�thout wr�tten perm�ss�on of the publ�sher �s proh�b�ted.

The publ�sher does not assume and hereby d�scla�ms any l�ab�l�ty to any party for any loss or damage caused by any error or om�ss�on �n th�s manual, whether such error results from negl�gence, acc�dent, or any other cause.

Publ�cat�on Date: March 1, 2006

Record the following information for warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equ�pment Ser�al #: ___________________________________

March 2006


��

TABLE OF CONTENTS

Page #

1. Introduction 1

2. Safety and Health 4

3. Principles of Operation 10

4. Operating Techniques 19

5. Equipment Selection 30

6. Important Process Variables 37

7. Advantages and Limitations 46

8. Troubleshooting 48


�v March 2006

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March 2006


v

!!

WARNINGS

Fumes from the a�r carbon-arc process are of var�ous types and strengths, depend�ng on the k�nd of base metal be�ng worked on. To ensure your safety, do not breathe these fumes. Vent�late near the arc to protect a�r carbon-arc operators and others �n the area. Somet�mes, operators may need to use spec�al breath�ng equ�pment. Be sure to test the a�r to ensure �t �s free of dangerous fumes.

SECTION 1: INTRODUCTION

Process Description

The a�r carbon-arc process (CAC-A) removes metal phys�cally not chem�cally (as �n oxy-fuel cutt�ng - OFC). Goug�ng or cutt�ng occurs when the �ntense heat of the arc between the carbon electrode and the workp�ece melts part of the workp�ece. Meanwh�le, a�r passes through the arc qu�ckly enough to blow the molten mater�al away.

S�nce the a�r carbon-arc process doesn’t need ox�dat�on to ma�nta�n the cut, �t can gouge or cut metals that the OFC process can’t. Most common metals - carbon steel, sta�nless steel, many copper alloys and cast �rons - can be cut us�ng the a�r carbon-arc process. The metal removal rate depends on the melt�ng rate and the a�r jet’s effic�ency �n remov�ng molten metal. The a�r must l�ft the molten metal clear of the arc before the metal sol�d�fies.

History

A�r carbon-arc goug�ng began �n the 1940’s, grow�ng out of an ex�st�ng process, carbon-arc cutt�ng. Need�ng to remove several hundred feet of flat, cracked, sta�nless steel weld, Myron Stepath, a weld�ng eng�neer, developed a�r carbon-arc goug�ng.


1-2 March 2006

Before, carbon-arc cutt�ng had been used to remove overhead and vert�cal defect�ve welds and r�vet heads. The carbon-arc melted the metal, and grav�ty moved away the molten metal.

Then Stepath reasoned that an a�r jet could prov�de the force to remove metal ly�ng flat. A d�rect current electrode negat�ve carbon-arc was tr�ed, and an a�r blast was prov�ded by a second operator, d�rect�ng an a�r nozzle at the molten pool.

Th�s attempt was unsuccessful because the arc was not as stable as a carbon-weld�ng arc. Next, Stepath tr�ed d�rect current electrode pos�t�ve. The result was a�r carbon-arc goug�ng. The bas�c pr�nc�ple rema�ns the same today, but the equ�pment has been �mproved and the number of appl�cat�ons expanded.

In 1948, Myron Stepath �ntroduced the first a�r carbon-arc torch to the weld�ng �ndustry. In 1949, Stepath and two assoc�ates founded the Arca�r® Company.

No longer were two operators needed. The compressed a�r came through the torch and out beneath the electrode. Th�s new tool saved t�me on weld backgoug�ng, crack removal, and repa�r of other weld defects on carbon, alloy and sta�nless steel. Prev�ously, such work had been done by gr�nd�ng or ch�pp�ng. As the process became more popular, torches were des�gned for more effic�ent, cleaner metal removal and for greater operator comfort.

March 2006


1-3

Applications

Industry has enthus�ast�cally adopted a�r carbon-arc goug�ng and has found many uses for the process: �n metal fabr�cat�on and cast�ng fin�sh�ng, �n chem�cal and petroleum technology, �n construct�on, m�n�ng, general repa�r and ma�ntenance.

Arca�r® Torches and Electrodes are used throughout the world, anywhere metal �s gouged, grooved, severed, or removed from a surface.

The a�r carbon-arc process �s flex�ble, effic�ent, and cost effect�ve on pract�cally any metal: carbon steel, sta�nless steel and other ferrous alloys; gray, malleable and duct�le �ron; alum�num; n�ckel; copper alloys and other nonferrous metals.


2-4 March 2006

Section 2: SAFETY AND HEALTH

Introduction

Safe pract�ces �n weld�ng and cutt�ng processes, such as a�r carbon-arc, �s covered �n ANSl Z49.1, “Safety in Welding and Cutting”, and ANSl 249.2, “Fire Prevention in Use of Welding and Cutting Processes.” A�r carbon-arc operators and the�r superv�sors should adhere to the safe pract�ces d�scussed �n these documents.

Other hazards �n arc weld�ng and cutt�ng are br�efly d�scussed �n th�s sect�on.

Properly Install, Use, and Maintain Equipment

Ser�ous �njury or death may result �f goug�ng and cutt�ng equ�pment �s not properly �nstalled, used and ma�nta�ned. M�suse of th�s equ�pment and other unsafe pract�ces can be hazardous. The operator, superv�sor and helper must read and understand the follow�ng safety warn�ngs and �nstruct�ons before �nstall�ng or us�ng any a�r carbon-arc torch or equ�pment.

The goug�ng cutt�ng process �s used �n many potent�ally dangerous env�ronments such as elevated he�ghts, areas of l�m�ted vent�lat�on, close quarters, around water, �n host�le env�ronments, etc., and �t �s �mportant that the operators are aware of the dangers assoc�ated �n work�ng �n these types

March 2006


2-5

of cond�t�ons. Be certa�n that the operator(s) are tra�ned �n safe pract�ces for env�ronments �n wh�ch they are expected to work and under competent superv�s�on.

It �s essent�al that the operator, superv�sor and others �n the work area are aware of the dangers of the a�r carbon-arc process. Tra�n�ng and proper superv�s�on are �mportant for a safe work place. Keep these �nstruct�ons for future use. Add�t�onal recommended safety and operat�ng �nformat�on �s referenced �n each sect�on.

WARNING !!

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH

Install and ma�nta�n equ�pment �n accordance w�th the Nat�onal Electr�cal Code NFPA 70 and local codes. Do not serv�ce or repa�r equ�pment w�th power on. Do not operate equ�pment w�th protect�ve �nsulators or covers removed.Serv�ce or repa�r to equ�pment must be done by qual�fied and/or tra�ned personnel only.

ElectrodesKeep carbon electrodes dry. If yours are damp, bake them for 10 hours at 300oF (176oC). Wet electrodes may shatter.


2-6 March 2006

Do not contact electr�cally l�ve parts. Do not touch electrode w�th bare sk�n and electr�cal ground at the same t�me. Always wear dry weld�ng gloves �n good cond�t�on. Alum�n�zed protect�ve cloth�ng can become part of the electr�cal path. Keep oxygen cyl�nders, cha�ns, w�re ropes, cranes, ho�sts. and elevators away from any part of the electr�cal c�rcu�t. All ground connect�ons must be checked per�od�cally to determ�ne that they are mechan�cally strong and electr�cally adequate for the requ�red current.

When engaged �n alternat�ng current goug�ng/cutt�ng under wet cond�t�ons or warm surround�ngs where persp�rat�on �s a factor, the use of rel�able automat�c controls for reduc�ng no load voltage �s recommended to reduce shock hazard. When the goug�ng/cutt�ng process requ�res values of open c�rcu�t voltages �n alternat�ng current mach�nes h�gher than 80 volts, and d�rect current mach�nes h�gher than 100 volts, means must be prov�ded to prevent the operator from mak�ng acc�dental contact w�th the h�gh voltage by adequate �nsulat�on or other means.

When goug�ng �s to be suspended for any substant�al per�od of t�me, such as dur�ng lunch or overn�ght, all electrodes should be removed from the torch and the torch carefully located so that acc�dental contact cannot occur. The torch must be d�sconnected from the power source when not �n use. Never �mmerse a�r carbon-arc torches or electrodes �n water.

March 2006


2-7

WARNING !!

SMOKE, FUMES AND GASES CAN BE DANGEROUS TO YOUR HEALTH

Ventilation Hazards

Keep smoke, fumes and gases from the breath�ng area. Fumes from the goug�ng process are of var�ous types and strengths, depend�ng on the k�nd of base metal be�ng worked on. To ensure your safety, do not breathe these fumes. Vent�lat�on must be adequate to remove smoke, fumes and gases dur�ng the operat�on to protect goug�ng operators and others �n the area.

Vapors of chlor�nated solvents can form the tox�c gas “Phosgene” when exposed to ultrav�olet rad�at�on from an electr�c arc. All solvents, degreasers and potent�al sources of these vapors must be removed from the operat�ng area.

Fumes produced by cutt�ng part�cularly �n confined places can cause d�scomfort and phys�cal harm �f �nhaled over an extended per�od of t�me. Prov�de adequate vent�lat�on �n the goug�ng/cutt�ng area. Use a�r-suppl�ed resp�rators �f vent�lat�on �s not adequate to remove all fumes and gases.


2-8 March 2006

Never vent�late w�th oxygen, because oxygen supports and v�gorously accelerates fire.

WARNING !!

NOISE CAN DAMAGE HEARING

Personal Protective Equipment and Clothing

No�se from the a�r carbon-arc process can damage your hear�ng. Wear protect�ve hear�ng dev�ces to ensure protect�on when no�se levels exceed OSHA standards. Adequate hear�ng protect�on dev�ces must be worn by operators and surround�ng personnel to ensure personal protect�on aga�nst no�se.

March 2006


2-9

PERMISSIBLE NOISE EXPOSUREDurat�on Per Sound LevelDay (�n hours) DBA

Slow Response8 906 924 953 972 1001-1/2 1021 1051/4 or less 115

WARNING !!

ARC RAYS, HOT SLAG AND SPARKS CAN INJURE EYES AND BURN SKIN

The goug�ng/cutt�ng processes produce extreme local�zed heat and strong ultrav�olet rays. Never attempt to gouge/cut w�thout a weld�ng helmet w�th the proper lens, that compl�es w�th federal gu�del�nes. A number 12 to 14 shade filter lens prov�des the best protect�on aga�nst arc rad�at�on. When �n a confined area, prevent the reflected arc rays from enter�ng


2-10 March 2006

around the helmet. Make sure others are protected from arc rays and sparks. Approved sh�eld�ng curta�ns and appropr�ate goggles should be used to prov�de protect�on to others �n the surround�ng area and operators of nearby equ�pment.

Sk�n should also be protected from arc rays, heat and molten metal. Always wear protect�ve gloves and cloth�ng wh�ch w�ll not allow sk�n to become exposed. All pockets should be closed and cuffs sewn shut. Leather aprons, sleeves, legg�ngs, etc. should be worn for out-of-pos�t�on goug�ng/cutt�ng or for heavy metal-removal operat�ons us�ng large electrodes. H�gh top work shoes prov�de adequate protect�on from foot burns. For added protect�on use leather spats. Flammable ha�r preparat�ons should not be used when goug�ng/cutt�ng. Wear ear plugs to protect ears from sparks.

Shielding Booths

Where the work perm�ts, the arc welder should be enclosed �n an �nd�v�dual booth pa�nted w�th a fin�sh of low reflect�v�ty such as z�nc ox�de, an �mportant factor for absorb�ng ultrav�olet rad�at�ons, and lamp black, or shall be enclosed w�th noncombust�ble screens s�m�larly pa�nted.

March 2006


2-11

WARNING !!

WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS

Fire and Burn Hazards

Causes of fire and explos�on are; combust�bles reached by the arc, flame, fly�ng sparks, hot slag or heated mater�als. Remove combust�bles from the work area and/or prov�de a fire watch. Avo�d o�ly or greasy cloth�ng as a spark may �gn�te them. Have a fire ext�ngu�sher nearby, and know how to use �t.

Be alert to the danger of conduct�on or rad�at�on, for example �f goug�ng/cutt�ng �s to be done on a metal wall, part�t�on, ce�l�ng or roof, precaut�ons must be taken to prevent �gn�t�on of combust�bles on the other s�de. Do not gouge/cut conta�ners that have held combust�bles. All hollow spaces, cav�t�es and conta�ners should be vented pr�or to goug�ng/cutt�ng to perm�t the escape of a�r or gases. Purg�ng w�th �nert gas �s recommended.

Never use oxygen In an air carbon-arc torch.


2-12 March 2006

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March 2006


2-13

Use only compressed a�r. Use of combust�ble compressed gases can cause explos�ons result�ng �n personal �njury or death.

SAFETY AND OPERATING REFERENCES1. Code of Federal Regulations. (OSHA) Section 29 Part 1910.95, 132, 133, 134, 139, 251, 252, 253, 254 AND, 1000. U.S. Government Printing Office, Washington, DC 204022. ANSl Z49.1 "Safety In Welding and Cutting"3. ANSI Z87.1 "Practice for Occupational and Educational Eye and Face Protection."4. ANSl Z88.2 "Standard Practice for Respiratory Protection." American National Standards Institute, 1430 Broadway, New York, NY 10018.5. AWS C5.3 "Recommended Practices for Air Carbon-Arc Gouging and Cutting."6. AWS F4.1 "Recommended Safe Practices for Welding and Cutting Containers." The American Welding Society, 550 NW Lejeune RD., P.O.Box 351040, Miami FL. 331357. NFPA 51B "Fire Prevention in Cutting and Welding Processes” National Fire Protection Association, Battery Park. Quincy MA 022698. CSA Standard W117.2, "Safety in Welding. Cutting and Allied Processes" Canadian Standards Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3

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3-14 March 2006

SECTION 3: PRINCIPLES OF OPERATION

General

L�ke arc weld�ng, CAC-A uses an �ntense arc to create a molten pool on the workp�ece. Compressed a�r blows away th�s molten metal.

The process requ�res a weld�ng power source, a�r compressor, carbon electrode and goug�ng torch. F�gure 1 shows how the components are usually arranged:

FIGURE 1

March 2006


3-15

Cut or gouge only �n the d�rect�on of a�r flow. The electrode angle w�ll vary, depend�ng on the appl�cat�on. The operator should ma�nta�n the correct arc length to enable a�r to remove molten metal. See F�gure 2.

FIGURE 2

Power Sources

S�ngle-phase mach�nes w�th low open-c�rcu�t voltage may not work for a�r carbon-arc goug�ng (CAC-A). However, any three-phase weld�ng power source of suffic�ent capac�ty may be used for a�r carbon-arc goug�ng. The open-c�rcu�t voltage should be h�gher than the requ�red arc voltage to allow for a voltage drop �n the c�rcu�t. The arc voltage used �n a�r carbon-arc goug�ng and cutt�ng ranges from a low of 35 to a h�gh of 56 volts (V); thus the open-c�rcu�t voltage should be at least


3-16 March 2006

Tab

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120

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March 2006


3-17

1600

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1800

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ld b

e us

ed.


3-18 March 2006

60V. The actual arc voltage �n a�r carbon-arc goug�ng and cutt�ng �s governed by arc length and the type of goug�ng.

Except for spec�al uses d�scussed later, CAC-A �s used w�th DCEP (reverse polar�ty). The electrode should extend at most 7 �n. (178mm) from the goug�ng torch w�th the a�r jet between the electrode and workp�ece. A m�n�mum extens�on of 2” should be used. Damage to the torch parts w�ll occur �f the st�ckout of the electrode �s less than the 2”.

Compressed Air

Use ord�nary compressed a�r for a�r carbon-arc goug�ng. Normal pressures range between 80 ps� (551.6kPa) and 100 ps� (690kPa) at the torch; h�gher pressures may be used, but they don’t remove metal more effic�ently. Use 60 ps� (413.7kPa) w�th the l�ght-duty manual torch. Don’t use pressures th�s low w�th general duty torches.

Regardless of the pressure used w�th manual torches, the a�r hose supply�ng a�r to the cable assembly connected to the torch body should have an �ns�de d�ameter (ID) of at least 3/8 �n. (6.4mm).

Mechan�zed torches w�th automat�c arc-length control should have an a�r-supply hose w�th a m�n�mum ID of 1/2 �n. (12 mm).

March 2006


3-19

Table 1 g�ves the consumpt�on rates of compressed a�r for the manual and mechan�zed torches and the compressor power rat�ng for �nterm�ttent and cont�nuous use. Be sure the compressor’s rece�ver tank �s large enough for the compressor rat�ng.

Electrodes

There are three types of electrodes.

DC copper-coated electrodes:Th�s type �s most w�dely used because of �ts comparat�vely long electrode l�fe, stable arc character�st�cs and groove un�form�ty. These electrodes are made from m�x�ng carbon and graph�te w�th a b�nder. Bak�ng th�s m�xture produces dense, homogeneous graph�te electrodes of low electr�cal res�stance, wh�ch are then coated w�th a controlled th�ckness of copper. These electrodes are ava�lable �n these d�ameters:

1/8” (3.2 mm), 5/32” (4.0 mm), 3/16” (4.8 mm), 1/4” (6.4 mm), 5/16” (7.9 mm), 3/8” (9.5 mm), 1/2” (12.7 mm)

Jo�nted electrodes work w�thout stub loss. They are furn�shed w�th a female socket and a match�ng male tang, and come �n the follow�ng d�ameters:

5/16” (7.9 mm), 3/8” (9.5 mm), 1/2” (12.7 mm), 5/8” (15.9 mm), 3/4” (19.1 mm), and 1” (25.4 mm)


3-20 March 2006

Flat (rectangular) coated electrodes come �n these s�zes:

5/32” (4.0 mm) x 3/8” (9.5 mm) and 3/16” (4.8 mm) x 5/8” (1 5.9 mm)

These electrodes make rectangular grooves and remove weld re�nforcements.

DC pla�n electrodes:These electrodes are used �n d�ameters of less than 3/8 �n. (9.5 mm). Dur�ng goug�ng they consume more rap�dly than coated electrodes. They are made l�ke the coated electrodes, but w�thout the copper coat�ng. Pla�n electrodes are ava�lable �n these d�ameters:

5/32” (4.0 mm), 3/16” (4.8 mm),1/4” (6.4 mm), 5/16” (7.9 mm),3/8” (9.5 mm)

AC coated electrodes:These electrodes are made from carbon, graph�te and a spec�al b�nder. Rare-earth mater�als are added to ensure arc stab�l�zat�on when us�ng alternat�ng current. These electrodes, coated w�th copper, are ava�lable �n these d�ameters:

3/16” (4.8 mm), 1/4” (6.4 mm) and 3/8” (9.5 mm)

March 2006


3-21

Tabl

e 3

- Sug

gest

ed C

urre

nt R

ange

s Fo

r Com

mon

ly U

sed

Elec

trode

Typ

es A

nd S

izes

Elec

trode

Dia

met

erDC

Ele

ctro

de W

ith D

CEP

AC E

lect

rode

With

AC

AC E

lect

rode

With

DCE

N

in.

mm

Min

imum

Am

psM

axim

um

Amps

Min

imum

Am

psM

axim

um

Amps

Min

imum

Am

psM

axim

um

Amps

1/8

3.2

6090

5/32

4.0

9015

0

3/16

4.8

200

250

200

250

150

180

1/4

6.4

300

400

300

400

200

250

5/16

7.9

350

450

3/8

9.5

450

600

350

450

300

400

1/2

12.7

800

1000

5/8

15.9

1000

1250

3/4

19.1

1250

1600

125

.416

0022

00


3-22 March 2006

Welding Cable Leads

Table 2 g�ves the recommended number and s�zes of weld�ng leads for d�fferent currents and lengths.

Manual Gouging TorchesA manual torch �s shown �n F�g. 3. The electrode �s held �n a sw�vel head, conta�n�ng one or more a�r holes, so that, regardless of the angle of the electrode to the goug�ng torch, the a�r jet stays al�gned w�th the electrode.

Torches w�th two heads (the a�r jet �s on two s�des of the electrode) or w�th a fixed angle between the electrode and the holder, are better for some uses - e.g. remov�ng pads and r�sers from large cast�ngs (padwash�ng).

Torches are usually a�r cooled. For h�gh-current appl�cat�ons, water-cooled cable assembl�es may be used w�th heavy-duty torches.

FIGURE 3

March 2006


4-23

SECTION 4: OPERATING TECHNIQUES

Controlling Automatic Gouging Torches

There are two methods of controll�ng automat�c a�r carbon-arc goug�ng torches. E�ther method can make grooves of cons�stent depth to a tolerance of +/-0.025 �n. (+/- 0.64 mm). These automat�c un�ts are used to ach�eve h�gh qual�ty gouges and �ncrease product�on. (See F�gure 4) The methods are as follows:

A) An amperage-controlled method wh�ch ma�nta�ns the arc current by amperage s�gnals through sol�d-state controls. Th�s method controls the electrode feed speed, wh�ch ma�nta�ns the preset amperage. It �s run w�th constant-voltage (CP) power sources only.

B) A voltage-controlled method that ma�nta�ns arc length by voltage s�gnals through sol�d-state electron�c controls. Th�s method controls the electrode feed speed, wh�ch ma�nta�ns the preset voltage. It can run w�th constant current (CC) power suppl�es.

The N6000 Automat�c Goug�ng System developed by Arca�r® can run on e�ther “CC” or “CP”.


4-24 March 2006

FIGURE 4

Gouging With manual Torches

The electrode should be gr�pped, as shown �n F�gure 2, so a max�mum of 7 �n. (178 mm) extends from the torch.

For alum�num, th�s extens�on should be 3 �n. (76.5 mm). Table 3 shows suggested currents for the d�fferent electrode types and s�zes.

The a�r jet should be turned on before str�k�ng the arc, and the torch should be held as shown �n F�gure 5. The electrode

March 2006


4-25

slopes back from the d�rect�on of travel w�th the a�r jet beh�nd the electrode.

FIGURE 5

Dur�ng goug�ng, the a�r jet sweeps beneath the electrode end and removes all molten metal. The arc may be struck by l�ghtly touch�ng the electrode to the workp�ece. The electrode should not be drawn back once the arc �s struck.

Goug�ng �s d�fferent from arc weld�ng �n that metal �s removed, not depos�ted. A short arc should be ma�nta�ned by work�ng �n the d�rect�on of the cut fast enough to keep up w�th metal removal. Stead�ness of movement controls the smoothnessof the result�ng cut.


4-26 March 2006

For goug�ng vert�cally, the goug�ng torch should be held as shown �n F�gure 6. Goug�ng should be done downh�ll, perm�tt�ng grav�ty to help remove the molten metal.

Vert�cal goug�ng may be done uph�ll, but do�ng so �s d�fficult. Goug�ng hor�zontally may be done e�ther to the r�ght or left, but always w�th forehand goug�ng.

FIGURE 6

In goug�ng to the left, the torch should be held as shown �n F�gure 7. In goug�ng to the r�ght, the torch should be reversed. Pos�t�on the a�r jet beh�nd the electrode. When goug�ng �n the overhead pos�t�on, as shown �n F�gure 8, the

March 2006


4-27

electrode and torch should be held so molten metal won’t dr�p on the operator’s glove.

FIGURE 7

The groove’s depth �s controlled by travel speed. Grooves up to 1 �n. (25 mm) deep may be made. However, the deeper the groove, the more exper�enced the operator needs to be. Slow travel speed w�ll produce a deep groove. Fast travel speeds w�ll produce a shallow groove. The w�dth of the groove �s determ�ned by the s�ze of the electrode used. The groove �s usually about 1/8 �n. (3.2 mm) w�der than the electrode’s


4-28 March 2006

d�ameter. A w�der groove may be made w�th a small electrode that �s osc�llated �n a c�rcular or weave mot�on.

When goug�ng, a push angle of 35 degrees from the surface of the workp�ece should be used for most appl�cat�ons. A steady rest w�ll ensure a smoothly gouged surface, espec�ally �n the overhead pos�t�on.

FIGURE 8

Proper travel speed depends on the s�ze of the electrode, on the base metal, on amperage and on a�r pressure. Proper speed, produc�ng a smooth h�ss�ng sound, w�ll result �n a good gouge.

March 2006


4-29

Severing

F�gure 9 shows the electrode ready for sever�ng. The sever�ng techn�que �s l�ke goug�ng, except the operator holds the electrode at a steeper angle, between 70 and 80 degrees to the surface of the workp�ece.

FIGURE 9

For cutt�ng th�ck nonferrous metals, the electrode should be held perpend�cular to the workp�ece, w�th the a�r jet favor�ng the s�de you w�sh to use. W�th the electrode �n th�s pos�t�on, the operator can sever the metal by mov�ng the arc up and down w�th a saw�ng mot�on.


4-30 March 2006

Washing

In us�ng the a�r carbon-arc process for remov�ng metal from large areas, surfac�ng metal and r�ser pads on cast�ngs, the operator should pos�t�on the electrode as shown �n F�gure 10. Weave the electrode from s�de to s�de wh�le push�ng forward at the depth des�red. In the pad-wash�ng operat�on, use an angle of 15 to 70 degrees to the workp�ece. The 15-degree angle �s used for l�ght fin�sh�ng passes, wh�le steeper angles allow deeper rough goug�ng to be done w�th greater ease.

FIGURE 10

Well-su�ted for th�s appl�cat�on are goug�ng torches w�th fixed-angle heads that hold the electrode at the correct angle. W�th other types of torches, be sure to keep the a�r beh�nd the electrode. The stead�ness of the operator determ�nes the smoothness of the surface produced.

March 2006


4-31

BevelingFor one bevel�ng method, used for th�ck plates, the electrode should be held, as �n F�gure 11 (a), w�th a travel angle of 90 degrees and a work angle equal to the bevel angle. The a�r jet should be between the electrode and the workp�ece.

The second method, used for th�n plates, �s shown �n F�gure ll,(b). The torch should be parallel to the edge be�ng beveled and the electrode angle should equal the bevel angle. The a�r jet should be between the electrode and the workp�ece surface.

FIGURE 11


4-32 March 2006

Tab

le 4

-Aut

omat

ic C

AC-A

U-G

roov

e Op

erat

ing

Data

E

LECT

RODE

D

ESIR

ED D

EPTH

S

PEED

IN/M

IN.

AM

PS

INCH

M

M

INCH

M

M

INCH

M

M

DC

5/

167.

941/

8 3

.18

6

5

165

1

400

5/

167.

943/

16 4

.76

4

5

114

3

400

5/

167.

941/

4 6

.35

3

6

914

4

00

5/16

7.94

5/16

7.9

4

33

8

38

400

5/

167.

947/

16 1

1.11

2

2.5

5

72

400

3/

89.

531/

8 3

.18

7

0

177

8

500

3/

89.

533/

16 4

.76

4

4

111

8

500

3/

89.

531/

4 6

.35

3

5

889

5

00

3/8

9.53

3/8

9.5

3

20

5

08

500

3/

89.

539/

16 1

4.29

1

7.5

4

45

500

1/

212

.71/

8 3

.18

9

6

243

8

850

1/

212

.71/

4 6

.35

5

7

144

8

850

1/

212

.73/

8 9

.53

3

5

889

8

50

1/2

12.7

1/2

12.7

2461

085

0

March 2006


4-33

1/2

12.7

3/4

19.0

517

.544

585

05/

815

.88

1/4

6.35

7218

2912

505/

815

.88

3/8

9.53

4812

1912

505/

815

.88

1/2

12.7

3794

012

505/

815

.88

5/8

15.8

830

762

1250

5/8

15.8

815

/16

23.8

119

.549

512

503/

419

.05

1/4

6.35

7218

2914

003/

419

.05

3/8

9.38

4210

6814

003/

419

.05

1/2

12.7

3486

514

003/

419

.05

5/8

15.8

827

687

1400

3/4

19.0

53/

419

.05

2256

014

003/

419

.05

1 1/

828

.58

1433

014

00If

you

wan

t a g

roov

e de

pth

grea

ter t

han

1-1/

2 t�m

es th

e d�

amet

er o

f the

ele

ctro

de b

e�ng

use

d,

mak

e th

e gr

oove

�n tw

o or

mor

e pa

sses

Tabu

lat�o

ns a

re b

ased

on

the

labo

rato

ry c

ond�

t�ons

. Us

e th

�s �n

form

at�o

n as

a g

u�de

and

adj

ust

for fi

eld

var�a

nce.


4-34 March 2006

Tabl

e 5

- Aut

omat

ic C

AC-A

J-G

roov

e Op

erat

ing

Data

Mat

’lEl

ectro

de D

ata

Elec

trode

Ove

rhan

g (in

ch) P

ass

Pow

er D

ata

Trav

el S

peed

(ipm

)Ai

r

Size

Size

Angl

eSt

ick

Out

12

3Am

psVo

lts1

23

Pass

Ov

eral

l Sp

eed

CFM

PSI

3/8

5/16

453.

0.0

6345

042

.065

6547

60

1/2

5/16

453.

0.0

6345

042

.035

3547

60

5/8

3/8

453.

0.0

63.0

6360

042

.050

5025

4760

3/4

3/8

453.

0.0

63.0

6360

042

.037

3718

.547

60

15/

845

3.0

.125

.125

1250

42.0

4040

2047

60

1.5

5/8

453.

0.0

63.0

63.0

6312

5042

.047

4747

1647

60

2.0

5/8

453.

0.1

25.1

25.1

2512

5042

.028

2828

9.5

4760

March 2006


5-35

SECTION 5: EQUIPMENT SELECTION

Gouging TorchChosen for the job be�ng done, torches range from l�ght-duty farm and body-shop s�zes to extra heavy-duty foundry torches. Here �s a gu�de for torch use:

Angle-Arc® Torches:

K2000TM - L�ght-duty general purpose torch - accepts 1/8” (3.2 mm) to 1/4” (6.5 mm) round electrodes and 3/8” (9.5 mm) flat electrodes. Max�mum of 450 amperes.

K3000TM - Med�um-duty general purpose torch - accepts 5/32” (3.97 mm) to 3/8” (9.5 mm) round electrodes and 3/8” (9.5 mm) flat electrodes. Max�mum of 600 amperes.

K4000® - Heavy-duty general purpose torch - accepts 5/32” (3.97 mm) to 1/2” (12.7 mm) round electrodes and 3/8” (9.5 mm) and 5/8” (15.9 mm) flat electrodes. Max�mum of 1000 amperes.

Foundry-Heavy Duty.. . Tr�-Arc®

General foundry work and heavy-duty fabr�cat�on. L�m�ted to 1600 amps w�th a�r-cooled cables and 2000 amps w�th water-cooled cables.


5-36 March 2006

Automat�c...Arca�r-Mat�c® N6000Edge preparat�ons and backgoug�ng, h�gh qual�ty and h�gh product�v�ty uses. Used w�th 5/16” - through 3/4” jo�nted carbons.

Power Sources

Any three-phase weld�ng power source w�th enough capac�ty may be used for the a�r carbon-arc goug�ng process. However, be sure the open c�rcu�t voltage �s h�gh enough to allow for a voltage drop �n the c�rcu�t. Some constant voltage w�th droop�ng character�st�cs requ�re very h�gh OCV to run a�r carbon-arc goug�ng equ�pment. S�ngle-phase power sources are usually too small for th�s process.

Power sources �n conjunct�on w�th mechan�zed goug�ng should be 100% duty cycle for the requ�red amperage.

DC...constant current (motor generator, rect�fier, or res�stor gr�d un�t).Preferred power supply for all electrode s�zes.

DC...constant voltage (motor generator or rect�fier).Usable only for 5/16 �n. (7.9 mm) and larger d�ameter electrodes. May cause carbon depos�ts w�th smaller electrodes. Not su�table for automat�c torches w�th voltage control only.

March 2006


5-37

AC...AC constant current (transformer).Recommended for AC electrodes only.

AC/DC transformer rect�fiersDC suppl�ed from three-phase transformer rect�fier sources �s sat�sfactory, but DC from s�ngle-phase suppl�es g�ves unsat�sfactory arc character�st�cs. AC output from AC/DC �s sat�sfactory, prov�ded AC electrodes are used.

Automatic Systems

Automat�c systems are often used �n today’s fabr�cat�on �ndustry. These systems offer a h�gh qual�ty, h�gh-product�v�ty alternat�ve to manual goug�ng. There are two types of systems to be cons�dered, both operat�ng on a s�gnal from the arc to control goug�ng.

Dual-Signal System

W�th th�s type of automat�c system, e�ther constant current (CC) or constant voltage (CV) power suppl�es can be used. When on CC, the arc length �s ma�nta�ned through a voltage-s�gnal system. A predeterm�ned voltage sett�ng �s set on the system controller, wh�ch then advances or retracts the electrode through a stepp�ng motor to ma�nta�n the arc length. On a CV power supply, amperage sens�ng controls the feed or retract of the electrode to ma�nta�n the r�ght arc current.


5-38 March 2006

Single Signal System

L�ke the dual-s�gnal system, th�s system also ma�nta�ns arc length through a voltage s�gnal. It w�ll not, however, operate w�th an amperage s�gnal. Th�s type of system operates only on a CC power supply.

Advantages

Automat�c CAC-A systems ensure better product�v�ty and qual�ty. The systems can do out-of-pos�t�on goug�ng. They do well at mak�ng long gouges �n flat work p�eces w�th a mov�ng goug�ng apparatus and for mak�ng c�rcular gouges �n p�pes and tanks w�th the goug�ng apparatus rema�n�ng stat�onary.

They make an even U-groove shape and can control depth of groove to w�th�n + /- 0.025 �n. (+ /- 0.64 mm). Tables 4 and 5 show operat�ng �nformat�on for both U and J-grooves.

March 2006


6-39

SECTION 6: IMPORTANT PROCESS VARIABLES

Process Variables

L�ke any thermal-cutt�ng process, a�r carbon-arc goug�ng �s sens�t�ve to var�ables �n operat�on. Var�ables can cause changes �n the fin�shed gouge that range from undetectable to unacceptable results. Here are some var�ables �n a�r carbon-arc process:

Electrode D�ameter - Determ�nes the s�ze of the groove.

Amperage - Determ�ned by the d�ameter of electrode be�ng used. Th�s current flow melts the base metal.

Voltage - The pressure beh�nd the amperage, or arc force. Determ�ned by arc length on CC power suppl�es and set on CV power suppl�es.

A�r Pressure and Flow Rate - The med�um for remov�ng molten metal.

Travel Speed - Determ�nes the depth/qual�ty of a fin�shed groove.

Electrode Travel and Work Angle - Can determ�ne groove shape.


6-40 March 2006

Electrode Extens�on - Affects metal removal rates and qual�ty of groove.

Base Metal - Affects many other var�ables.

Electrode Diameter and Type

The electrode’s s�ze and type determ�ne groove s�ze. The electrode also affects product�v�ty, groove qual�ty and metal-removal rates. The w�dth of the groove w�ll be about 1/8 �n. w�der than the d�ameter of the electrode.

Choose the proper electrode by the s�ze of the groove you want. Ava�lable power w�ll d�ctate the outer l�m�t. For example, a 1/2 �n. w�de, 1/4 �n. deep groove 10 �n, long could be made manually �n two passes us�ng a 1/4 �n. electrode, or �n one pass w�th a 3/8 �n. d�ameter electrode. In the first case, the best goug�ng rate would be 10 �nches per m�nute (�pm) d�v�ded by 2 or 5 �pm. The latter travel speed �s 17 �pm.

Here the 3/8” d�ameter electrode g�ves a 200% �ncrease �n goug�ng rate that could offset the added electrode cost. Automat�c systems further �ncrease the product�v�ty rate through fin�te control of the arc voltage.

Amperage

The goug�ng amperage �s the process’s melt�ng force. It �s affected by electrode s�ze. If the amperage were set too

March 2006


6-41

low for the electrode s�ze, the melt�ng rate of the base metal would be �nadequate and free carbon depos�ts would occur. Although the base metal would melt, a sett�ng too h�gh would rap�dly deter�orate the electrode wh�le reduc�ng the metal removed per electrode. Too h�gh a sett�ng could also substant�ally reduce torch l�fe.

Voltage

Is the pressure or arc force that enables the current to flow across the arc gap. CAC-A often requ�res a h�gher voltage than do most weld�ng processes. To ensure proper operat�on, use a power supply w�th h�gh enough open-c�rcu�t voltage to ma�nta�n a 28-volt operat�ng m�n�mum. Not enough voltage can create a sputter�ng arc or �t can prevent arc establ�shment, result�ng �n uneven grooves and probably free carbon depos�ts. These requ�re excess�ve gr�nd�ng to remove.

Air Pressure and Flow Rate

The a�r jet removes molten metal. Adequate pressure and flow rate are requ�red for proper results. Keep �n m�nd that a�r volume or (cfm) �s as �mportant as a�r pressure. Pressure �s the speed of a�r that moves the molten metal from the groove. If there �s not enough a�r volume or (cfm) to l�ft molten mater�al out of the groove, the pressure or veloc�ty cannot remove �t. The result �s excess�ve slag adhes�on and unnecessary gr�nd�ng to clean up the groove.


6-42 March 2006

Travel Speed

Affects the depth of the gouge and the qual�ty of the groove. The faster the travel of an electrode, the shallower the gouge. Use a smaller electrode, �f the travel speed �s too fast for the operator’s comfort, or try automat�c goug�ng. Mak�ng a groove too deep for the electrode’s d�ameter results �n a poor qual�ty groove that requ�res much gr�nd�ng.

Electrode Push Angle

The electrode’s push angle can vary somewhat. When goug�ng manually, a steeper angle tends to g�ve a more V-shaped groove, wh�le w�th the automat�c system a steeper angle g�ves a sl�ghtly deeper groove at the same travel speed.

Base Metals

Gouging Recommendations

The follow�ng procedures are recommended:

For Carbon steel and low alloy steel, such as ASTM A514 and A517 - Use DC electrodes w�th DCEP (electrode pos�t�ve). AC electrodes w�th an AC transformer can be used, but for th�s appl�cat�on, AC �s only half as effic�ent as DC.

For Sta�nless steel - Same as for carbon steel.

March 2006


6-43

For Cast �ron, �nclud�ng malleable and duct�le �ron (nodular) - Use 1/2” or larger electrodes at the h�ghest rated amperage.

Use spec�al techn�ques when goug�ng these metals. The push angle should be at least 70-degrees off the workp�ece. The depth of the cut should not exceed 1/2 �nch per pass.

For Copper alloys (copper content 60% and under) - Use DC electrodes w�th DCEN (electrode negat�ve) at the electrode’s h�ghest amperage rat�ng.

For Copper alloys (copper content over 60% or s�ze of workp�ece �s large) - Use DC electrodes w�th DCEN at max�mum amperage rat�ng of the electrode or use AC electrodes w�th AC.

For Alum�num Bronze and Alum�num N�ckel Bronze (spec�al naval propeller alloy) - Use DC electrodes w�th DCEN.

For N�ckel alloys (n�ckel content �s over 80% of mass) - Use AC electrodes w�th AC.

For N�ckel alloys (n�ckel content less than 80% of mass) - Use DC electrodes w�th DCEP.

For Magnes�um alloys - Use DC electrodes w�th DCEP. Before weld�ng, w�re brush groove.


6-44 March 2006

For Alum�num - Use DC electrodes w�th DCEP. You must w�re brush w�th sta�nless w�re brushes before weld�ng. Electrode extens�on (length of electrode between torch and work) should not exceed 3 �n. (76.2 mm). DC electrodes w�th DCEN can also be used.

For T�tan�um, Z�rcon�um, Hafn�um, and the�r alloys - Don’t cut or gouge to prepare for weld�ng or remelt�ng unless you mechan�cally remove surface layer from cut surface.

NOTE

If you preheat for weld�ng, preheat for goug�ng.

Effects of the CAC-A Process on Base Metals

Here �s what happens metallurg�cally dur�ng goug�ng and cutt�ng w�th the a�r carbon-arc process.

W�th DCEP and the correspond�ng half cycle of alternat�ng current, the current flow carr�es �on�zed carbon atoms from the electrode to the base metal. The free carbon part�cles are qu�ckly absorbed by the melted base metal. S�nce th�s absorpt�on �s sure to happen, be sure that all carbur�zed molten metal �s removed from the kerf, us�ng the a�r jet.

When the a�r carbon-arc process �s used under �mproper cond�t�ons, carbur�zed molten metal may be left on the workp�ece surface. Its color �s usually a dull gray-black, �n

March 2006


6-45

Tabl

e 6

- Res

ults

of C

orro

sion

Tes

ting

on T

ype

304L

Sta

inle

ss.

Spec

imen

Id

entifi

catio

nW

eldi

ng

Proc

ess

Wel

ding

Po

sitio

nRo

otPr

epar

atio

nCo

rros

ion

Rate

(per

mon

th)

�n.

mm

HC1

GMAW

Hor�z

onta

lCA

C-A

Goug

�ng

0.00

0593

0.01

505

HC2

GTAW

Hor�z

onta

lCA

C-A

Goug

�ng

0.00

0594

0.01

509

HG1

GMAW

Hor�z

onta

lGr

�nd�

ng0.

0006

460.

0164

HG2

GTAW

Hor�z

onta

lGr

�nd�

ng0.

0006

180.

0157

VC1

GMAW

Vert�

cal

CAC-

A Go

ug�n

g0.

0006

860.

0174

2VC

2SM

AWVe

rt�ca

lCA

C-A

Goug

�ng

0.00

0627

0.01

593

VGSM

AWVe

rt�ca

lGr

�nd�

ng0.

0006

670.

0169

5OG

SMAW

Over

head

Gr�n

d�ng

0.00

0632

0.01

605

OCSM

AWOv

erhe

adCA

C-A

Goug

�ng

0.00

0645

0.01

638


6-46 March 2006

contrast to the br�ght blue of the properly made groove. Inadequate a�r flow may leave small pools of carbur�zed metal �n the bottom of the groove. Irregular electrode travel, espec�ally �n a manual operat�on, may cause r�pples �n the groove wall that trap the carbur�zed metal. F�nally, an �mproper electrode push angle may cause small beads of carbur�zed metal to rema�n on the groove’s edge.

If th�s carbur�zed metal stays on the cut surface, �t can affect the workp�ece when �t �s welded aga�n. These effects depend on the amount of carbur�zed metal present, the weld�ng process used, the k�nd of base metal, and the weld qual�ty requ�red. Although you m�ght th�nk filler metal put on the surface dur�ng weld�ng would absorb small pools or beads of carbur�zed metal, work w�th steel base metals shows that trace metal w�th only 1% carbon may stay along the weld �nterface. Such flaws may lessen weld strength and toughness.

Copper from copper-coated electrodes doesn’t transfer to the cut surface �n base metal, unless the process �s �mproperly used.

Remove carbur�zed metal from a cut surface by gr�nd�ng, but prevent hav�ng to do so by goug�ng properly �n the r�ght cond�t�ons.

Stud�es were conducted on sta�nless steel to determ�ne whether a�r carbon-arc goug�ng, carr�ed out �n the prescr�bed manner, adversely affects corros�on res�stance. The stud�es

March 2006


6-47

show no s�gn�ficant d�fference �n the corros�on rates for welds prepared by CAC-A and those prepared by gr�nd�ng (See Table 6). Had carbon been absorbed, the corros�on rates for welds backgouged by CAC-A would have been s�gn�ficantly h�gher. In the stud�es, type 304L sta�nless steel was welded us�ng several processes. Backgoug�ng of the jo�nt was performed by a�r carbon-arc goug�ng and by gr�nd�ng. Spec�mens from the jo�nts were subjected to the bo�l�ng-65%-n�tr�c-ac�d test.

Compared to oxy-fuel gas cutt�ng, CAC-A �s a lower-heat-�nput process. Therefore, a work p�ece gouged or cut by CAC-A �s less d�storted. The mach�n�ng of low carbon and non-hardenable steels �s not affected by the a�r carbon-arc process. W�th cast �ron and h�gh-carbon steels, however, th�s process may cause enough harden�ng to make the cut surface tough to mach�ne. St�ll, because the hardened zone �s shallow (approx�mately, 0.06 �n. / 0.15 mm), a cutt�ng tool can penetrate the hardened zone to remove the hardened surface.


7-48 March 2006

SECTION 7: ADVANTAGES AND LIMITATIONS

Advantages

Fast - F�ve t�mes faster than ch�pp�ng. Gouges a groove 3/8 �n. (9.5 mm) deep at over 2 ft. (600 mm) per m�nute.

Eas�ly controllable - Prec�sely removes defects. Defects are clearly v�s�ble �n the groove and may be followed w�th ease. The depth of the cut �s eas�ly controlled and slag does not hamper the cutt�ng act�on.

Low cost - Gas cyl�nders and regulators are unnecessary except �n field operat�ons.Econom�cal to operate - No oxygen or fuel gas requ�red. The welder or weld�ng operator may also do the goug�ng or cutt�ng.

Easy to operate - Welders operate the equ�pment after only a few m�nutes and become sk�lled �n a few days. The torch conta�ns an a�r-control valve and sw�vel head that perm�t chang�ng the electrode angle to su�t the job wh�le ma�nta�n�ng a�r-jet al�gnment.Compact- Not much larger than a sh�elded metal arc weld�ng torch.

Versat�le - Use �t anywhere you weld. May be operated �n spaces too restr�cted for a ch�pp�ng hammer or an oxy-fuel

March 2006


7-49

gas cutt�ng torch. Needs no d�fficult adjustments for use on d�fferent metals.

Clean cutt�ng - Result�ng surface �s clean and smooth. Weld�ng or braz�ng �s often done w�thout further gr�nd�ng or clean�ng of the groove.


7-50 March 2006

AREA

S OF

APP

LICA

TION

The

a�r c

arbo

n-ar

c go

ug�n

g pr

oces

s ha

s be

en u

sed

�nAg

ricul

ture

Prep

ar�n

g fo

r wel

d�ng

the

jo�n

ts o

f bro

ken

met

als

on fa

rm

mac

h�ne

ry.

Rem

ov�n

g su

rfac

e w

elds

. Se

ver�n

g m

etal

s.Ai

rcra

ftM

a�nt

a�n�

ng g

roun

d eq

u�pm

ent a

nd a

�rpor

t stru

ctur

es.

Re-w

ork�

ng d

�es

and

fixtu

res.

Auto

mot

ive

Ma�

nta�

n�ng

equ

�pm

ent.

Pre

par�n

g br

oken

cas

t-�ro

n pa

rts.

Seve

r�ng

met

als.

Rem

ov�n

g br

oken

or s

e�ze

d be

ar�n

g ra

ces,

col

lars

, etc

., fro

m s

hafts

.Bo

iler S

hops

Rem

ov�n

g r�v

ets

and

defe

ct�v

e w

elds

. Pr

epar

�ng

crac

ks

for r

e-w

eld�

ng.

Rem

ov�n

g tu

bes

from

tube

she

ets.

Brew

erie

sM

a�nt

a�n�

ng e

qu�p

men

t, va

ts, p

�p�n

g, e

tc..

Cutt�

ng a

nd

goug

�ng

all t

ypes

of m

etal

s, e

spec

�ally

sta

�nle

ss s

teel

s.Ch

emic

al P

lant

sPr

epar

�ng

equ�

pmen

t and

p�p

�ng

of s

ta�n

less

ste

el a

nd

nonf

erro

us m

etal

s fo

r rep

a�r a

nd a

ltera

t�on

by w

eld�

ng.

March 2006


7-51

AREA

S OF

APP

LICA

TION

The

a�r c

arbo

n-ar

c go

ug�n

g pr

oces

s ha

s be

en u

sed

�nCo

nstru

ctio

nPr

epar

�ng

jo�n

ts fo

r wel

d�ng

. Re

mov

�ng

defe

cts

�n w

elds

. Fa

br�c

at�n

g w

�thou

t bev

el�n

g. R

emov

�ng

hold

�ng

cl�p

s,

l�ft�n

g pa

ds, e

tc.,

w�th

out d

amag

e to

pad

s or

stru

ctur

e.

Ma�

nta�

n�ng

equ

�pm

ent.

Dred

ging

Ma�

nta�

n�ng

equ

�pm

ent.

Prep

ar�n

g m

anga

nese

ste

el

parts

for r

epa�

r by

wel

d�ng

. Re

mov

�ng

surf

ac�n

g fo

r re

surf

ac�n

g.Fo

undr

ies

Padw

ash�

ng. R

emov

�ng

fins

and

r�ser

s. R

emov

�ng

crac

ks,

sand

poc

kets

, and

oth

er d

efec

ts fr

om c

ast�n

g. M

a�nt

a�n�

ng

equ�

pmen

t.Su

rfaci

ngRe

mov

�ng

old

surf

ace

wel

ds fo

r re-

surf

ac�n

g. P

repa

r�ng

sta�

nles

s an

d m

anga

nese

ste

els

for w

eld�

ng. R

emov

�ng

defe

ct�v

e w

elds

.


7-52 March 2006

AREA

S OF

APP

LICA

TION

The

a�r c

arbo

n-ar

c go

ug�n

g pr

oces

s ha

s be

en u

sed

�nLu

mbe

r Ind

ustr

yM

a�nt

a�n�

ng e

qu�p

men

t. Re

mov

�ng

surf

ace

wel

ds fo

r re

surf

ac�n

g. D

�sm

antl�

ng d

amag

ed e

qu�p

men

t for

repa

�r an

d re

use.

Pre

par�n

g ca

st �r

on fo

r wel

d�ng

or

braz

�ng

wel

d�ng

.M

aint

enan

ce S

hops

D�sm

antl�

ng a

nd re

mod

el�n

g eq

u�pm

ent.

Rem

ov�n

g su

rfac

�ng

wel

ds fo

r res

urfa

c�ng

. Sev

er�n

g m

etal

s.

Prep

ar�n

g da

mag

ed a

reas

for r

epa�

r wel

d�ng

.Ar

my/

Mar

ines

Rem

ov�n

g au

sten

�t�c

wel

d m

etal

. Bac

kgou

g�ng

wel

ds

for w

eld�

ng th

e se

cond

s�d

e. S

alva

g�ng

arm

or p

late

s.

Seve

r�ng

met

als.

Rem

ov�n

g de

fect

s �n

wel

dsan

d ca

st�n

gs.

March 2006


7-53

AREA

S OF

APP

LICA

TION

The

a�r c

arbo

n-ar

c go

ug�n

g pr

oces

s ha

s be

en u

sed

�nNa

vy/C

oast

Gua

rdRe

mov

�ng

defe

cts

�n w

elds

and

cas

t�ngs

. Bac

kgou

g�ng

to

wel

d th

e se

cond

s�d

e. R

emov

�ng

aust

en�t�

c w

eld

met

als.

Rem

ov�n

g pa

deye

s, d

ogs,

etc

., w

�thou

t dam

age

to a

ttach

men

ts o

r to

ex�s

t�ng

stru

ctur

es. G

roov

�ng

of th

�n

plat

e fo

r wel

d�ng

. Rem

ov�n

g er

oded

are

as o

n sh

�ps’

hul

ls,

ster

n tu

bes,

stru

ts, r

udde

rs, a

nd p

rope

llers

for r

epa�

r by

wel

d�ng

. Rem

ov�n

g of

bul

khea

ds, p

atch

es, a

nd a

cces

s ha

tche

s fo

r reu

se b

y da

mag

e co

ntro

l.M

inin

gM

a�nt

a�n�

ng e

qu�p

men

t. Go

ug�n

g m

anga

nese

ste

els,

cas

t �ro

n, a

nd a

ll no

nfer

rous

met

als.

Rem

ov�n

g su

rfac

e w

elds

an

d ha

rdfa

c�ng

.


7-54 March 2006

AREA

S OF

APP

LICA

TION

The

a�r c

arbo

n-ar

c go

ug�n

g pr

oces

s ha

s be

en u

sed

�nOi

l Refi

nerie

sRe

mov

�ng

defe

ct�v

e w

elds

. Cut

t�ng

and

goug

�ng

sta�

nles

s an

d au

sten

�t�c

wel

ds. C

utt�n

g ou

t or p

atch

�ng

tank

bo

ttom

s an

d co

ke-a

nd-p

�pe

st�ll

s. R

emov

�ng

l�ner

s, b

o�le

r an

d he

at-e

xcha

nger

tube

s, a

nd r�

vets

. Rem

ov�n

g de

fect

s an

d pr

epar

�ng

brea

ks �n

cas

t�ngs

for r

epa�

r by

wel

d�ng

. Se

ver�n

g no

nfer

rous

met

als.

Rem

ov�n

g r�s

ers

on c

ast�n

gs.

Prep

ar�n

g th

e su

rfac

e of

ero

ded

and

corr

oded

are

as o

n ac

�d-p

lant

equ

�pm

ent f

or re

bu�ld

�ng

by w

eld�

ng.

Oil D

rillin

gGr

oov�

ng fo

r wel

d�ng

of p

late

s. R

emov

�ng

dr�ll

col

lars

. Re

mov

�ng

surf

ace

wel

ds fo

r re-

surf

ac�n

g. G

oug�

ng o

ut

defe

cts

and

groo

v�ng

edg

es o

f cas

t�ngs

(mud

pum

ps),

etc.

for w

eld�

ng. M

a�nt

a�n�

ng e

qu�p

men

t. Re

mov

�ng

fish

plat

es o

n tru

ck c

hass

�s fo

r ren

ewal

. Gro

ov�n

g of

bro

ken

edge

s fo

r re-

wel

d�ng

.Pa

ckin

g Ho

uses

Prep

ar�n

g eq

u�pm

ent,

vats

and

p�p

�ng

of s

ta�n

less

ste

el

and

nonf

erro

us m

etal

for w

eld�

ng.

March 2006


7-55

AREA

S OF

APP

LICA

TION

The

a�r c

arbo

n-ar

c go

ug�n

g pr

oces

s ha

s be

en u

sed

�nPo

wer

Pla

nts

Ma�

nta�

n�ng

equ

�pm

ent.

Groo

v�ng

of m

etal

for w

eld�

ng.

Goug

�ng

out c

ast�n

gs fo

r rep

a�r.

Rem

ov�n

g ca

v�t�e

s fro

m P

elto

n w

heel

s. R

emov

�ng

wel

ded

end

tube

s fro

m

tube

she

ets.

Rem

ov�n

g w

eld�

ng d

efec

ts. G

oug�

ng a

nd

prep

ar�n

g ca

st �r

on fo

r wel

d�ng

or b

raze

wel

d�ng

.Sa

lvag

e Ya

rds

Cutt�

ng s

crap

. Rem

ov�n

g w

elds

w�th

out �

njur

�ng

reus

able

st

ruct

ures

. Cut

t�ng

sta�

nles

s st

eel,

nonf

erro

us m

etal

s, a

nd

cast

�ron

.


7-56 March 2006

AREA

S OF

APP

LICA

TION

The

a�r c

arbo

n-ar

c go

ug�n

g pr

oces

s ha

s be

en u

sed

�nRa

ilroa

dsM

a�nt

a�n�

ng e

qu�p

men

t. Re

mov

�ng

jour

nal l

�ner

s, r�

vets

, w

elde

d en

d tu

bes

from

tube

she

ets.

Pre

par�n

g br

eaks

�n

bo�le

rs, fi

re b

oxes

, etc

., fo

r rep

a�r b

y w

eld�

ng. S

alva

g�ng

an

d re

scu�

ng a

fter e

qu�p

men

t wre

ckag

e. P

repa

r�ng

for

wel

d su

rfac

�ng

or �t

s re

mov

al fr

om fr

ogs,

sw

�tche

s,

and

ra�l

ends

. Pre

par�n

g m

anga

nese

ste

el fo

r wel

d�ng

. Re

mov

�ng

r�ser

pad

s an

d de

fect

s fro

m c

ast�n

gs �n

fo

undr

�es.

Pre

par�n

g w

orn

whe

els

for r

ebu�

ld�n

g by

w

eld�

ng.

Ship

build

ing

See

Navy

/Coa

st G

uard

Stai

nles

s Sh

ops

Cutt�

ng s

ta�n

less

ste

el. R

emov

�ng

defe

cts

�n s

ta�n

less

ste

el

cast

�ngs

and

wel

ds.

March 2006


7-57

AREA

S OF

APP

LICA

TION

The

a�r c

arbo

n-ar

c go

ug�n

g pr

oces

s ha

s be

en u

sed

�nSt

eel F

abric

atio

nW

eld�

ng a

nd fi

tt�ng

pla

tes

w�th

out b

evel

�ng

by

back

goug

�ng

the

seco

nd s

�de

to s

ound

met

al a

fter w

eld�

ng

the

first

s�d

e. R

emov

�ng

wel

ds fr

om e

x�st

�ng

stru

ctur

es

and

salv

ag�n

g un

dam

aged

mat

er�a

l for

reus

e. C

utt�n

g an

d go

ug�n

g al

l met

als

�n th

e sh

op a

nd a

t the

job

s�te

. M

a�nt

a�n�

ng e

qu�p

men

t.St

eel M

ills

Ma�

nta�

n�ng

equ

�pm

ent.

Cutt�

ng a

nd g

oug�

ng a

ll m

etal

s.

Was

h�ng

b�ll

ets

and

bloo

ms.

Rem

ov�n

g de

fect

s.W

ater

wor

ksPr

epar

�ng

brok

en e

qu�p

men

t for

repa

�r by

wel

d�ng

. Cu

tt�ng

and

gou

g�ng

all

met

als.

Cut

t�ng

cast

-�ron

p�p

e,

espe

c�al

ly c

oncr

ete

l�ned

. Re

mov

�ng

wel

ds s

o de

fect

�ve

p�pe

sec

t�ons

can

be

repl

aced

.W

eldi

ng S

hops

Rem

ov�n

g w

elds

. Cut

t�ng

all m

etal

s, e

spec

�ally

non

ferr

ous

met

als,

sta

�nle

ss s

teel

, and

cas

t �ro

n. G

oug�

ng b

evel

s an

d ba

ckgo

ug�n

g w

eld

root

s. R

emov

�ng

surf

ace

wel

d fo

r re-

surf

ac�n

g.


8-58 March 2006

Prob

lem

Larg

e fre

e-ca

rbon

de

posi

t at t

he

begi

nnin

g of

the

groo

ve.

An u

nste

ady

arc,

cau

sing

the

oper

ator

to u

se a

sl

ow tr

avel

spe

ed

even

on

shal

low

gr

oove

s.

Caus

eTh

e op

erat

or e

�ther

neg

lect

ed to

turn

on

the

a�r j

et b

efor

e st

r�k�n

g th

e ar

c,

or th

e to

rch

was

loca

ted

�mpr

oper

ly.

Carb

on ro

d no

t pos

�t�on

ed p

rope

rly �n

he

ad a

ssem

bly.

Not e

noug

h am

pera

ge fo

r the

el

ectro

de d

�am

eter

use

d (s

ee T

able

3)

. Wh�

le th

e lo

wes

t rec

omm

ende

d am

pera

ge m

ay b

e en

ough

, �t r

equ�

res

grea

ter o

pera

tor s

k�ll.

A m

�d-r

ange

am

pera

ge �s

bet

ter.

Solu

tion

The

a�r s

houl

d be

turn

ed o

n be

fore

st

r�k�n

g th

e ar

c an

d sh

ould

flow

bet

wee

n th

e el

ectro

de a

nd th

e w

orkp

�ece

.

Ensu

re c

arbo

n ro

d �s

sea

ted

�n g

roov

e �n

to

rch

head

.

If th

e de

s�re

d am

pera

ge c

anno

t be

obta

�ned

from

the

ava�

labl

e po

wer

sou

rce,

us

e th

e ne

xt s

mal

ler d

�am

eter

ele

ctro

de

or p

aral

lel t

wo

or m

ore

wel

d�ng

pow

er

supp

l�es.

Trou

bles

hoot

ing

March 2006


8-59

Prob

lem

Erra

tic g

roov

e w

ith

the

arc

wan

der-

ing

from

sid

e to

si

de a

nd w

ith th

e el

ectro

de h

eatin

g up

rapi

dly.

Inte

rmitt

ent a

rc

actio

n re

sulti

ng in

an

irre

gula

r gro

ove

surfa

ce.

Caus

eTh

e pr

oces

s w

as a

ppar

ently

use

d w

�th D

CEN

(ele

ctro

de n

egat

�ve)

.

The

trave

l spe

ed w

as to

o sl

ow �n

m

anua

l gou

g�ng

. The

ope

rato

r pr

obab

ly s

et h

�s h

and

on o

ther

wor

k fo

r bal

ance

as

sh�e

lded

met

al-a

rc

wel

ders

do.

S�n

ce th

e sp

eed

of a

�r ca

rbon

-arc

gou

g�ng

�s m

uch

fast

er

than

sh�

elde

d m

etal

-arc

wel

d�ng

, fr�

ct�o

n be

twee

n th

e gl

oved

han

d an

d th

e w

orkp

�ece

may

cau

se a

je

rky

forw

ard

mot

�on.

Th�

s m

ot�o

n ca

uses

the

gap

betw

een

the

elec

trode

an

d w

orkp

�ece

to b

ecom

e to

o lar

ge

to m

a�nta

�n th

e ar

c. P

oor g

roun

d co

nnec

t�on.

Solu

tion

Goug

�ng

proc

ess

shou

ld b

e do

ne w

�th

DCEP

(Ele

ctro

de p

os�t�

ve) w

hene

ver

poss

�ble

. D�

rect

cur

rent

ele

ctro

des

shou

ld b

e us

ed w

�th D

CEP

(ele

ctro

de

pos�

t�ve)

on

all m

etal

s, e

xcep

t for

a fe

w

copp

er a

lloys

suc

h as

Sup

erst

on a

nd

N�al

�te. R

efer

to p

age

30 &

31.

The

oper

ator

sho

uld

stan

d co

mfo

rtabl

y so

the�

r arm

s m

ove

freel

y an

d th

e�r

glov

es d

o no

t dra

g on

the

wor

kp�e

ce. I

f yo

u us

e m

echa

n�ze

d eq

u�pm

ent,

chec

k Ta

ble

4 fo

r pro

per o

pera

t�ng

cond

�t�on

s.

Insp

ect g

roun

d cl

amps

and

lead

(s) t

o en

sure

con

nect

�on

prop

er.

Trou

bles

hoot

ing

(Con

t.)


8-60 March 2006

Prob

lem

In g

ougi

ng, f

ree

carb

on d

epos

its

at v

aryi

ng g

roov

e in

terv

als;

in p

ad

-was

hing

, fre

e ca

rbon

dep

osits

at

var

ious

spo

ts

on th

e w

ashe

d su

rface

.

Irreg

ular

gro

ove:

to

o de

ep, t

hen

too

shal

low

.

Caus

eTh

e el

ectro

de h

as s

horte

d ou

t on

the

wor

kp�e

ce. I

n m

anua

l gou

g�ng

, th�

s co

nd�t�

on �s

cau

sed

by a

trav

el s

peed

ex

cess

�ve

for t

he a

mpe

rage

use

d an

d fo

r the

dep

th o

f the

gro

ove

be�n

g m

ade.

In m

echa

n�ze

d op

erat

�ons

, th

e co

nd�t�

on �s

cau

sed

e�th

er b

y ex

cess

�ve

trave

l spe

ed o

r by

us�n

g a

flat-c

urve

con

stan

t-vol

tage

pow

er

sour

ce fo

r a s

mal

l d�a

met

er e

lect

rode

5/

16 �n

. (7.

9 m

m).

In p

adw

ash�

ng,

th�s

sho

rt�ng

out

�s c

ause

d by

hol

d�ng

th

e el

ectro

de a

t too

sm

all a

pus

h an

gle.

The

oper

ator

was

uns

tead

y.

Solu

tion

Use

an e

lect

rode

-to-w

ork

angl

eof

15

to 7

0 de

gree

s. A

sm

alle

r ang

le

�ncr

ease

s th

e ar

c�ng

are

a,re

duc�

ng th

e cu

rren

t den

s�ty

; th�

s re

duct

�on

�n a

rc-c

urre

nt d

ens�

tyre

qu�re

s a

grea

t dec

reas

e �n

arc

le

ngth

, to

the

po�n

t of s

hort

c�rc

u�t�n

g. K

eep

a pr

oper

arc

gap

.

The

oper

ator

sho

uld

assu

me

a co

mfo

rtabl

e po

s�t�o

n w

h�le

gou

g�ng

.

Trou

bles

hoot

ing

(Con

t.)

March 2006


8-61

Prob

lem

Slag

adh

erin

g to

th

e ed

ges

of th

e gr

oove

.

Caus

eSl

ag e

ject

�on

was

�nad

equa

te. F

or

adeq

uate

sla

g ej

ect�o

n, k

eep

a pr

oper

a�

r pre

ssur

e an

d flo

w ra

te (c

fm).

A�r

pres

sure

bet

wee

n 80

and

100

ps�

(5

50-6

90 k

Pa) m

ay n

ot e

ffect

�vel

y ej

ect a

ll of

the

slag

�f th

e vo

lum

e �s

�n

suffi

c�en

t.

Solu

tion

To d

el�v

er a

dequ

ate

volu

me,

the

a�r

hose

feed

�ng

the

conc

entr�

c ca

ble

asse

mbl

y a

m�n

�mum

�ns�

de d

�am

eter

of

3/8

�n. (

9.5

mm

) for

man

ual

torc

hes.

For

aut

omat

�c to

rche

s, th

e m

�n�m

um h

ose

ID s

houl

d be

1/2

�n

. (12

.7 m

m).

Be s

ure

the

a�r j

et �s

d�

rect

ed p

aral

lel t

o th

e go

uge

area

. Do

not

favo

r one

s�d

e un

less

you

w

ant t

o m

�n�m

�ze s

lag

from

adh

er�n

g to

one

s�d

e of

the

cut.

Trou

bles

hoot

ing

(Con

t.)


62 March 2006

NOTES

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