6

Flame Cutting Principles

In the majority of fabricating shops and in the field, the Chapter Objectives
welder must be able to do manual flame cutting (Fig.6-1).
The oxyfuel gas cutting (OFC) torch has become a uni-
After completing this chapter, you will be able to:
versal tool. OFC is widely used for straight-line shape cut-
ting. It is also used as a means of scrapping obsolete metal 6-1 Describe oxyfuel cutting principles.
structures. OFC devices can be used to fabricate metal 6-2 Identify oxyfuel cutting equipment.
structures (Fig. 6-2). 6-3 Explain the safety issues of oxyfuel cutting.
Cutting processes have made it possible to fabricate 6-4 Describe various support equipment for
structures requiring heavy thicknesses of metal from oxyfuel cutting.
rolled steel. Formerly, these structures had to be cast. The
6-5 Identify various cutting techniques.
combination of cutting and welding processes created an
6-6 Describe the oxygen lance cutting process.
industry devoted to the fabrication of heavy machinery
and equipment from rolled steel. Oxyfuel gas cutting
increases the speed of fabrication and eliminates many
costly joining, shaping, and finishing operations.

Oxyacetylene and Other

Fuel Gas Cutting
Oxyacetylene cutting (OFC-A) is limited to the cutting
of ferrous materials (materials containing iron). Stain-
less steel, manganese steels, and nonferrous materials
are not readily cut because they do not oxidize rapidly.
Many of these materials may be cut by the arc or water
jet process. Most ferrous materials have an affinity for
oxygen. Even under normal conditions the oxygen in the

166
 A BOU T WEL DIN G

Fig. 6-1 A construction worker using an OFC torch to scrap an
obsolete riveted structure. lowefoto/Alamy Stock Photo
ASME Code
Welding and brazing qualifications are a
crucial part of the ASME code now called the Boiler and
Pressure Vessel Code. This code, which began in 1915,
explains what an operators qualifications must be and
proper procedures. It also provides requirements for new
construction of pressure-related items so that you will be
safer when you use them.

flame is high enough to melt the iron oxide so that it runs

off as molten dross, exposing more iron to the oxygen jet.
Thus the jet can be moved along to produce a clean cut.
Cutting is really a process of very rapid rusting. It is
thus considered a chemical cutting process, unlike the arc
and water jet cutting that uses a mechanical method of
materials removal.
The oxyfuel gas cutting process makes use of several
other fuel (flammable) gases in addition to acetylene.
These fuel gases include propane, natural gas, propylene,
and Mapp gas. Refer to Table 6-1 for a review of the char-
acteristics of these gases and their distribution.

Equipment
Oxyfuel gas cutting requires the following equipment:
Single-purpose cutting torch, Figs. 6-3 and 6-4, or a
welding torch to which an adaptable cutting head has
been attached
Fig. 6-2 Cutting bar stock which is part of the structural steel on
a building construction job. Johner Images/Getty Images
Flint lighter
Oxygen regulator
Acetylene regulator
Oxygen welding hose with couplings attached to
air attacks these materials to form an iron oxide that we each end
recognize as rust. Thus, the rusting process is a slow Acetylene welding hose with couplings attached
form of oxygen cutting. At elevated temperatures the to each end
oxidation process is increased. Oxygen cutting requires Flame arresters and check valves
that the part to be cut be raised to a temperature of
1,500 to 1,600F (usually a cherry red). A stream of
pure oxygen is directed onto the hot metal causing it to
burn rapidly.
Steel burns in pure oxygen after having reached its
kindling temperature just as paper burns in air. The main J OB T IP
difference is that burning paper gives off carbon dioxide
Experience Required
and water vapor. These products of combustion are gas-
The American Welding Society has
eous and pass off into the air. When steel burns, however, a certificate that shows prospective employers a certain
it gives off iron oxide which is solid at room temperature. skill level that has been achieved. It can be a ticket to that
Its melting point is below the melting point of steel. The first interview.
heat generated by the burning iron and the oxyacetylene

Flame Cutting Principles Chapter 6167

 Table 6-1 Properties of Common Fuel Gases

Methylacetylene Pro-
Acetylene Propane Propylene padiene (MPS) Natural Gas
Chemical formula C2H2 C8H8 C3H6 C3H4 CH4 (Methane)
(Methylacetylene,
propadiene)
Neutral flame temperature, F 5,600 4,580 5,200 5,200 4,600
Primary flame heat emission, Btu/ft 3
507 255 433 517 11
Secondary flame heat emission, Btu/ft 3
963 2,243 1,938 1,889 989
Total heat value (after vaporization), Btu/ft3 1,470 2,498 2,371 2,406 1,000
Total heat value (after vaporization), Btu/lb 21,500 21,800 21,100 21,100 23,900
Total oxygen required (neutral flame), 2.5 5.0 4.5 4.0 2.0
vol. O2/vol. fuel
Oxygen supplied through torch (neutral flame),
vol. O2/vol. fuel 1.1 3.5 2.6 2.5 1.5
ft3 oxygen/lb fuel (60F) 16.0 30.3 23.0 22.1 35.4
Maximum allowable regulator pressure, p.s.i. 15 150 150 150 Line
Explosive limits in air, % 2.58.0 2.39.5 2.010 3.410.8 5.314
Volume-to-weight ratio, ft3/lb (60F) 14.6 8.66 8.9 8.85 23.6
Specific gravity of gas (60F) Air = 1 0.906 1.52 1.48 1.48 0.62

As modified from the American Welding Society, Welding Handbook, Vol. 2, 8th ed., Table 14.1, p. 454.

3 Cutting TorchThe cutting torch, Fig. 6-4A,

6 premixes oxygen and acetylene or other fuel
1 The oxygen furnished to the preheating flame
8 4
7
2
5
Fig. 6-3 Equipment for oxyacetylene and other fuel gas cutting.
1. Cutting torch. 2. Cutting tip. 3. Oxygen regulator. 4. Acetylene
regulator. 5. Torch wrench. 6. Tank and regulator wrench. 7. Lighter.
8. Goggles. Thermadyne Industries, Inc.
Portable tank outfits are mounted on a truck simi-
lar to that shown in Fig. 5-21, page 151. Review pages
148160 in Chapter 5 concerning the regulators, hose,
and other equipment.
gases in the proportions necessary for cutting.
is regulated by a preheat valve on the side of the
handle. A high pressure oxygen valve operated
by a lever controls the oxygen.
On some torches the preheating oxygen and
acetylene mix in the cutting tip. The cutting
torch, Fig.6-4B, tip mixes the oxygen and acety-
lene of other fuel gases in the proportions neces-
sary for cutting.
The cutting head may be at a 45 or 90 angle
to the body of the torch. Torches with straight
heads may also be obtained.
Figure 6-5 illustrates the internal construc-
tion of a standard cutting torch.
On some jobs, such as pipe welding and re-
pair work, cutting is a small part of the welding
operation. For such jobs, the adaptable cutting
attachment is used for cutting. In a few seconds it can be
attached to the welding torch without disconnecting the
hose from the torch. The construction and operation of
the cutting attachment is similar to the type of cutting
torch in which the preheating gases mix in the handle.

168Chapter 6Flame Cutting Principles

 Cutting Tip Nut Cutting tips are designated as stan-
Tip
dard or high speed. The standard tip
Tip Nut
Torch Head has a straight bore cutting oxygen
Tip Mix port and is typically used with oxygen
Mixed
Cutting Oxygen pressures in the 30 to 60 p.s.i. range,
Preheat Three-Tube while the high speed tips have a di-
Gases Design
verging cutting oxygen port that flares
out toward the opening. This flaring
out allows much higher oxygen pres-
sure (60100 p.s.i.), while maintain-
ing a uniform oxygen jet at supersonic
velocities. These high speed tips are
Universal
Pressure
Preheat
Fuel Gas
Cutting typically used only for machine cut-
Oxygen
Mixer ting and will yield an increase in travel
Preheat
Oxygen speed of 20 percent over standard tips,
Fig. 6-8 (p. 172). The cutting oxygen
orifice size is not usually affected by
the type of fuel gas being used. How-
ever, the preheat orifices need to be of
Cutting
Oxygen the appropriate design for the type of
Handle
Lever fuel gas being used. The various fuel
gases require different volumes of
Handle
oxygen and fuel as shown in Table 6-2.
Cutting Tips used for acetylene are usually one
Oxygen
Lever
piece, while the other fuel cases may be
one- or two-piece tips. See Fig.6-8B.
Acetylene tips are flat on the flame
Preheat Preheat
Oxygen Preheat end. Tips for methylacetylene-propa-
Fuel Gas
Value Value Valves diene (MPS) have a flat surface on the
flame end. Most propylene tips have a
Oxygen
Fuel Gas
Inlet Inlet slight recess, and natural gas and pro-
pane tips usually have a deeper recess
Fuel Gas Oxygen Mixed Gas
or cupped end.
Tips may be obtained for flame ma-
Fig. 6-4A Typical premixing-type Fig. 6-4B Typical tip mixing-type cutting chining, gouging, scarfing, and rivet
cutting torch. Adapted from Welding torch. Adapted from Welding Handbook, Vol. 2,
Handbook, Vol. 2, 8th ed., p. 451, 8th ed., p. 451, fig. 14.2
cutting, Fig. 6-9 (p. 173).
fig. 14.2

Lighters The cutting torch should be lighted with a

Figure 6-6 (p. 171) illustrates the internal construction of
a standard adaptable cutting attachment.
Cutting Tips The cutting tip, Fig. 6-7 (p.171), has a cen-
tral hole through which the high pressure oxygen flows.
Around this center hole are a number of preheating flame
holes. Cutting tips may be obtained in various shapes and
sizes. The thicker the metal that is to be cut, the larger
the size of the center hole must be. Table6-2 (p.172) lists
different-sized cutting tips and the gas pressures appropri-
ate for them.
friction lighter, Fig. 6-3. The flints of friction lighters
can be easily replaced at small cost when worn out.
Matches should never be used because the thermal cut-
ters hand has to be too close to the torch tip and may be
burned when the gases ignite. There is also the danger
that the supply of matches that the thermal cutter may
be carrying in his or her pockets will ignite and cause
severe burns.
Goggles The thermal cutter must wear protective gog-
gles to prevent harm to his or her eyes from sparks, hot
particles of metal, and glare. Suitable goggles and lenses
are discussed in Chapter 5 (pp. 161162).

Flame Cutting Principles Chapter 6169

170

Needle Valve Gland Nut

Valve Stem Packing Washer

Valve Stem Handle

Needle Valve Spring

Needle Valve Stem Valve Spring Washer

Lever Lever
Lock Adjusting Wedge
Lever Lock
Medium Button
Mixer Cap
Pressure
Lever Lock Poppet Valve Gland
Mixer H.P. Oxygen Handle Head Rivet
Tube Poppet Valve Lever Bolt
Poppet Valve Stem Packing

Outlet Bushing
Poppet Valve Stem
Outlet Bushing

Cutting Head Poppet Valve Body

Mixed Gas Tube Gasket Poppet Valve Seat
Cutting Head Nut Handle Handle Poppet Valve Poppet Valve
Screw Tube Poppet Valve
Spring Seat Holder
Guide Cap
L-Unit Screw Type
Cutting Tip

Fig. 6-5 Internal construction of a standard oxyfuel gas cutting torch. Adapted from Thermadyne Holdings Corporation
 Poppet Valve Guide Cap
Poppet Valve Seat Holder
Poppet Valve Gasket
Poppet Valve Seat
Poppet Valve Spring Poppet Valve Stem Packing

Poppet Valve Gland

Poppet Valve Stem
Poppet Valve Lever

Poppet Valve
Lever Bolt

H.P. Gland Cutting Head

Cutting Head Nut Union Shank
Tube Packing
Cutting Head Tube
Snap Ring
O-Ring

O-Ring

Mixer Shell Union Nut

M.P. Mixer Valve Body
Fig. 6-6 Internal construction ofa Cutting Head Nut Anti-Friction Washer
standard oxyfuel gas adaptable cutting Mixer Nut
Needle Valve Assembly
attachment. Adapted from Thermadyne L Series Tips
Holdings Corporation

Gloves The heat coming from a cutting job may be very

intense. There may also be a shower of sparks and hot ma-
terial which makes it necessary for the thermal cutter to
protect his or her hands with gloves. For the best protec-
tion gloves should be of nonburnable material. It is com-
mon practice, however, to wear an ordinary canvas glove
with a cuff, which can be purchased at very small cost.
Gloves should be kept free from grease and oil be-
cause of the danger involved in contact with oxygen.

Oxyfuel Gas Cutting Machines

Fig. 6-7 Standard cutting tip attached to cutting torch head.
Thermadyne Industries, Inc.
S H OP TAL K
Safety
Todays consumers assume that you will
be working in the most environmentally friendly
way possible. Corporate responsibility means taking
precautions to prevent injury to the Earth and its
inhabitants.
A very large part of the cutting done today is performed
by oxyfuel gas cutting machines, Fig. 6-10. These ma-
chines have a device to hold the cutting torch and guide
it along the work at a uniform rate of speed. It is possible
to produce work of higher quality and at a greater speed
than with the hand cutting torch. Machines may be used
for cutting straight lines, bevels, circles, and other cuts of
varied shape.
Small portable cutting machines are used with only one
torch. Large permanent installations can make use of sev-
eral cutting torches to make a number of similar shapes at
the same time. A multiple-torch cutting machine and its
automatic controls are shown in Figs. 6-11 and 6-12.
Maximum productive capacity is achieved through the
use of stationary cutting machines developed for produc-
tion cutting of regular and irregular shapes of practically

Flame Cutting Principles Chapter 6171