Cutting and Gouging

Job knowledge 12:

Air Carbon Arc Gouging
The main difference between this gouging technique and the others is that a
separate air jet is used to eject molten metal from the groove.
Process description
Air carbon arc gouging works as
follows. An electric arc is generated
between the tip of a carbon
electrode and the workpiece. The
metal becomes molten and a high
velocity air jet streams down the
electrode to blow it away, thus
leaving a clean groove. The process
is simple to apply (using the same
equipment as MMA welding), has a
high metal removal rate, and
gouge profile can be closely
controlled. Disadvantages are that the air jet causes the molten metal to be
ejected over quite a large distance and, because of high currents (up to 2000A)
and high air pressures (80 to 100 psi), it can be very noisy.
Application
As air carbon arc gouging does not rely on oxidation it can be applied to a wide
range of metals. DC (electrode positive) is normally preferred for steel and
stainless steel but AC is more effective for cast iron, copper and nickel alloys.
Typical applications include back gouging, removal of surface and internal defects,
removal of excess weld metal and preparation of bevel edges for welding.
Electrode
The electrode is a graphite (carbon) rod which has
a copper coating to reduce electrode erosion.
Electrode diameter is selected according to
required depth and width of gouge. Cutting can be
precisely controlled and molten metal/dross is kept
to a minimum.
Power source
A DC power supply with electrode positive polarity
is most suitable. AC power sources which are also
constant current can be used but with special AC
type electrodes. The power source must have a constant current output
characteristic. If it does not, inadvertant touching of the electrode to the
workpiece will cause a high current surge sufficient to 'explode' the electrode tip.
This will disrupt the operation and cause carbon pick-up. As arc voltage can be
quite high (up to 50V), open circuit voltage of the power source should be over
60V.



Air supply
The gouging torch is normally operated with either a compressed air line or
separate bottled gas supply. Air supply pressure will be up to 100psi from the air
line but restricted to about 35psi from a bottled supply. Providing there is
sufficient air flow to remove molten metal, there are no advantages in using
higher pressure and flow rates.
Carbon pickup
Although carbon is picked up by the molten metal, the air stream will remove
carbon-rich metal from the groove to leave only minimal contamination of the
sidewalls. Poor gouging technique or insufficient air flow will result in carbon pick-
up with the risk of metallurgical problems, e.g high hardness and even cracking.
Typical operating data for air carbon arc gouging:
Gouging
dimensions Electrode
diameter (mm)
Current A
Note: DC
electrode Depth
(mm)
Width
(mm)
Carbon
electrode
consumed
(mm/min)
Gouging
speed
(mm/min)
6.4 275 6-7 9-10 120 609
8.0 350 7-8 10-11 114 711
9.5 425 9-10 12-13 100 660
Manual
13.0 550 12-13 18-19 76 508
8.0 300-400 2-9 3-8 100 1650-840
9.5 500 3-12 3-10 142 1650-635
13.0 850 3-15 3-13 82 1830-610
Automatic
16.0 1250 3-19 3-16 63 1830-710
Operation
Gouging is commenced by striking the electrode tip on to the workpiece surface to
initiate the arc. Unlike manual metal arc (MMA) welding the electrode tip is not
withdrawn to establish arc length. Molten metal directly under the electrode tip
(arc) is immediately blown away by the air stream. For effective metal removal, it
is important that the air stream is directed at the arc from behind the electrode
and sweeps under the tip of the electrode. The width of groove is determined by
the diameter of electrode, but depth is dictated by the angle of electrode to the
workpiece and rate of travel. Relatively high travel speeds are possible when a low
electrode angle is used. This produces a shallow groove: a steep angle results in a
deep groove and requires slower travel speed. Note, a steeply angled electrode
may give rise to carbon contamination.
Oscillating the electrode in a circular or restricted weave motion during gouging
can greatly increase gouging width. This is useful for removal of a weld or plate
imperfection that is wider than the electrode itself. It is important, however, that
weave width should not exceed four times the diameter of the electrode.The
groove surface should be relatively free of oxidised metal and can be considered
ready for welding without further preparation. Dressing by grinding the side-walls
of the gouge should be carried out if a carbon rich layer has been formed. Also,
dressing by grinding or another approved method will be necessary if working on
crack-sensitive material such as high strength, low alloy steel.


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