Oxyfuel Cutting

a Definition: To sever or remove metal through a hightemperature chemical reaction between oxygen and the
base metal.
a Abbreviation: OFC - OxyFuel Cutting
a With special equipment, OFC process can be used to cut
plates up to 7 foot thick. OFC can be used to cut
straight lines or curves because the oxygen jet provides
a 360 degree cutting edge.
a Study torch terminology and function shown by figures
14.1, 14.2 and 14.7.
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Kerf and Drag

a Kerf - The width of the oxyfuel cut. Factors influencing
the kerf include the type of tip used, the size of the
oxygen port, fuel and oxygen flow rates and travel
speed. (Metal thickness is an indirect factor.) The width
of the cut is very important to maintain dimensional
tolerance.
a Drag - When the travel speed is increased to the point
that the oxygen stream lags at the bottom of the cut,
the amount of lag is referred to as Drag. See figure
14.3. Some drag is generally acceptable, but excessive
drag will result in a poor quality cut.
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Kerf and Drag (cont.)

How it Works
a The oxyfuel cutting process relies upon 3 different, high
temperature, chemical reactions between the oxygen
and iron. Each reaction produces heat.
a The preheat flame is used to warm a localized spot to
the ignition temperature (also called kindling point).
This temperature is 1600F for iron.
a Upon reaching the ignition temperature, a stream of
high-purity oxygen initiates the chemical reactions and
the cutting action. At this point the process can be selfsustaining (the preheat flame is not required).
a The oxygen should be a minimum of 99.5% pure for
optimum cutting.
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Fuel Gases
a Functions of the fuel gas:
`Raise steel temperature to the ignition point.
`Add heat to the steel to aid cutting reaction.
`Shield the oxygen cutting stream from the air.
`Help remove rust, mill-scale and other contamination
from the steel surface.
a Several fuel gases are available. Each provides unique
properties, advantages and disadvantages.
a Study figure 14.4 - Types of oxyfuel flames. A neutral
flame is generally used for cutting.
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Factors to Consider when

Selecting a Fuel Gas
`Time required for preheat.
`Will the gas impair cutting speed?
`Cost and availability in the desired package.
`Cost of preheat oxygen needed to burn the gas
effectively.
`Ability to use the fuel for other operations (welding,
heating, brazing).
`Inherent safety factors (stability, etc.).
`Available equipment: Torches and Tips used must
be appropriate for the fuel selected.
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Fuel Gas Choices

a Acetylene (C2H2) - Widely used, good availability and
user familiarity, high flame temperature and heattransfer characteristics. Acetylene is unstable at
pressures above 15 psi gage pressure and has a wide
explosive limits range (2.5 to 80%).
a Methylacetylene-Propadiene Stabilized (MPS, C3H4) - A
mixture of several fuel gases with operating
characteristics similar to Acetylene. However it requires
about double the oxygen volume to achieve a neutral
flame (oxygen costs will be higher). Higher regulator
pressures may be used.
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Fuel Gas Choices (cont.)

a Natural Gas (mostly methane, CH4) - Produces a lower
temperature, less intense flame than acetylene. Thus
more gas must be used to achieve similar results. A
two-piece tip must be used. Natural gas is delivered via
low-pressure pipelines.
a Propane (C8H8) - Highest total heat value, but also
highest oxygen usage. Available in liquid form and
easily transported to remote work-sites. Narrow
explosive limits range (2.3 to 9.5%) and can be used at
high (150 psi) line pressure.
a Propylene (C3H6) - Sold under a variety of brand names
(MAPP gas, etc.). Similar to MPS.
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Advantages of OFC
aFaster than mechanical methods.
aCurved shapes and thick sections can be cut.
aLow cost equipment when compared to
mechanical tools.
aPortability of process.
aCan make abrupt changes in cut direction.
aLarge pieces can be cut in place.
aEconomical method for beveling weld joints.
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Disadvantages of OFC
a Poor dimensional tolerances when compared to
machine tools.
a Limited to readily oxidized metals (steel and cast
iron).
a Safety hazards associated with flames and hot slag.
a Ventilation and fume control required.
a Hardenable steels may be damaged by OFC.
a Process must be modified for alloy steels and cast
irons.
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Equipment
a Manual Equipment - Typically used for operations
that do not require a high degree of accuracy or cut
quality. Often used for maintenance chores, cutting
scrap metal, at remote locations and on large
cumbersome pieces.
a Mechanized Equipment - Used for accurate, high
quality work and large volume jobs. Most
fabrication shops have one or more mechanized
OFC cutting tools (line burner, pipe beveler, multiaxis cutting table).
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Manual Equipment
a Torches - Premixing or Tip mixing (fig. 14.1 & 14.2)
a Cutting Tips - Use the right type and size for the fuel
gas used and steel thickness. (fig. 14.5 & 14.6)
a Hoses for oxygen and fuel gas. (see p. 363)
a Regulators for oxygen and fuel gas. (see p. 364)
a Striker, tip cleaner, wrench, clamp.
a Personal protection equipment:
`tinted goggles shade 3 to 5
`gloves and leather, wool or cotton clothing).
`Steel toed boots.
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Mechanized Equipment
aIn addition to the equipment used for manual
cutting, the following are often found on
mechanized cutting apparatus:
`A machine to move the torch: usually motorized,
sometimes hand-cranked. (see figures 14.8 - 14.14)
`Special torch (fig. 14.7) and torch adjustments
`A cutting table to support work and catch slag.
`Automatic torch igniter.

aCutting machines can be portable or stationary.

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Operation -

Follow Manufacturers Instructions!

a Regulators - NEVER grease or oil a regulator. Keep them
clean. Do not hang anything (ex.: oil bottle) from a
regulator. Operate at the pressure recommended for the tip.
a Hoses - Use the proper size and type of hose for the cutting
torch and application. Keep hoses in good shape. Do not
fix with tape or other unapproved method.
a Flashback - Burning of the flame in or behind the torch
mixing chamber. Often caused by overheating the tip or
failure to purge the hoses prior to lighting torch. Serious
condition!
a Backfire - The momentary recession of the flame into the
torch tip. Clean the tip and torch. If condition continues
have torch serviced. Fairly common condition.
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Operation (cont. 1)
a Starting the Torch - Turn on the fuel gas slightly, ignite with
a spark lighter (never use matches or a cigarette lighter),
adjust the fuel and oxygen to achieve a neutral flame.
a Know the difference between a neutral, carburizing and
oxidizing flame. Read about flame adjustment, study fig.
14.4.
a Start at the edge when possible. Open oxygen stream when
the steel under the preheat flame is reddish yellow.
a Flame cones should be held 1/16 to 1/8 inch from the
surface. When piercing (not at an edge) remember to lift the
torch about 3/8 inch away from surface and slowly open the
cutting oxygen valve. This helps prevent tip clogging.
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Operation (cont. 2)
a Maintain tip-to-work distance. Move at a speed that
produces a steady spark stream.
a Sheet metal should be cut with the torch turned to a
sharp leading angle.
a Thin plate (3/16 to 7/16) should be cut with the torch
at a slight leading angle.
a Plate 1/2 and over should be cut with the torch
perpendicular to the surface.
a Use angle iron or other straight-edge for straight cuts
and bevels. Use upward progression for vertical cuts.
a Turning off the Torch - Remember O-A-O.
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Plate Beveling and Gouging

a The preheat flame is a more critical factor because the
the bevel angle increases the preheat efficiency
decreases. Special tips are available for steep angle,
large thickness applications.
a Multiple torches may be used to achieve the desired
joint bevel. Study figures 14.14 to 14.17.
a Oxy-Fuel Gouging is often used to back-gouge a weld
joint in preparation for a back weld. Gouging is also
used to remove defective sections of weld. Special tips
are used.
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Quality Indicators:
aProper Cut Angle
aFlatness of the cut
aSharpness of the cut at the preheat edge
aDimensional Tolerances of the cut shape
`Tolerances of 1/32 to 1/16 are achievable

aAdherence of slag
aCut surface uniformity
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Factors that Affect Cut Quality

`Type of Steel
`Thickness of Steel
`Quality of Steel
`Condition of Surface
`Intensity of preheat flame
`Cutting tip size
`Purity of Oxygen and flow rate
`Cleanliness and condition of tip
`Cutting speed and movement uniformity
`Study figures in book and on bulletin board.
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Materials
a Low-carbon steels are readily cut.
a Low-Alloy steels are generally easy to cut but may
harden and crack adjacent to the cut.
`Preheating (400 - 600F) is often used when cutting
low-alloy steels.
a Cast Iron - High carbon cast irons do not cut well using
techniques used for low-carbon steel.
`Use an oscillating motion (fig. 14.24), larger cutting
tip, a carburizing flame and higher flow rates.

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