Examples of Shape Cutting

Rectangle Square Circle Strips Single Taper

Double Taper Right Triangle Triangle Triangle Diamond

Hexagon Octagon Parallelogram Bevel End Gate

Gusset Corner Clip Half Circle Quarter Circle Segment

Bracket Parallel Curve Outside Curve Inside Curve Re-entrant Curve

Re-entrant Cut Re-entrant Cut Round Ends Double Circle Half Ring or Arc

Ellipse Square & Circle Inside Square Re-entrant Cut Square & Ellipse

Trolley Plate Splice Plate Corner Notch Circle & Slots Die

Link Slot Rosette Cross Mould

Special Curve Die Cam or Crank Gear Guard Hook

Fig. 17-35 Examples of shape cutting.

542 Chapter 17 Arc Cutting Principles and Arc Cutting Practice: Jobs 17-J1J7
 Job 17-J6 Gouging
Torch
with CAC-A
Stickout 7 in. Max
Electrode
Position the torch as shown in Fig. 17-38, p. 544.
Copper Peel Back Torch Heads (+)
3/4 in. to 2 in. DCEP on d.c.
Air
80 p.s.i. Objective
35 to 70
Always Under the Electrode To make a gouge in a butt joint to form a U-groove,
with acceptable quality to make a complete joint
Travel
penetration (CJP) weld that is capable of passing a
radiograph test. See the Job Drawing in Fig. 17-39,
Workpiece () p. 544.
Fig. 17-36 How a standard CAC-A torch works. Source: From Welding
Handbook, 9/e. General Job Information
Make a square groove butt joint with an E7018
electrode or substitute electrode or welding process
Compressed Air per your instructors instructions. This is to simulate
the making of a CJP weld. The practice is to gouge
Power to the proper depth to expose sound weld metal. This
Source may take several passes and should be done carefully
so that excessive gouging is not done. Additional plates
can be welded together to increase practice opportu-
Electrode Lead nity. If practice pieces are available in the scrap area,
DCEP or AC they can be used to simulate this job. If they have been
Carbon Electrode welded on both sides, just gouge out one weld to the
Concentric Cable
Torch Workpiece dimensions indicated on the Job Drawing. When the
Workpiece
Lead proper technique is used, the CAC-A process produces
little, if any, dross on the finished cut. If dross remains,
it is rich in carbon and must be removed. This can be
done with a chipping hammer or grinding. If you at-
tempt to weld through this dross, the resulting weld
Fig. 17-37 Typical air carbon arc cutting equipment setup. will be of very low quality. Use Table17-10 for proper
Source: American Welding Society, Welding Handbook, 9th Edition,
volume 2, page 653, fig. 15.8 settings.

Table 17-9 Job Outline: Plasma Arc Cutting Practice: Jobs 17-J1J5

Minimum Minimum Air

Job Type of Thickness Output Pressure and Text AWS
Number Job Material1 (in.) Rating Flow Rate Reference S.E.N.S.E. Reference2
17-J1 Square cut Carbon steel 3
8 25 A @ 90 V 60 p.s.i. @ 4.5 ft3/min 556 Advanced expert3
17-J2 Bevel cut Carbon steel 3
8 50 A @ 110 V 70 p.s.i. @ 5.3 ft3/min 556 Advanced expert3
17-J3 Gouging Carbon steel 3
8 50 A @ 110 V 70 p.s.i. @ 5.3 ft3/min 556 Advanced expert3
17-J4 Hole piercing Carbon steel 1
4 50 A @ 110 V 70 p.s.i. @ 5.3 ft /min
3
557 Advanced expert3
17-J5 Shape cutting Carbon steel 1
4 25 A @ 90 V 60 p.s.i. @ 4.5 ft3/min 557 Entry level

Once carbon steel has been mastered, practice on stainless steel and aluminum.
1

For AWS S.E.N.S.E., carbon steel, stainless steel, and aluminum must be mastered.
2

For advanced level, manual and machine PAC are required, and for expert level, pipe practice must also be included.
3

Source: From Welding Handbook, 9/e.

Arc Cutting Principles and Arc Cutting Practice: Jobs 17-J1J7 Chapter 17 543
 Job 17-J7 Weld
Removal with CAC-A

Objective
Remove weld metal with minimal gouging
into the base metal. See the Job Drawing in
Fig. 17-40.

General Job Information

Select appropriate fillet welds from scrap area.
A B If none are available, set up as per the Job Draw-
ing and weld prior to CAC-A gouging. Use ap-
propriate techniques similar to those used in the
Job Drawing.
Reduce the electrode to approximately 30,
and direct the electrode toward the center of
the fillet weld. Use sufficient travel speed to
maintain the arc while removing the weld with
minimal gouging into the base metal. You are
looking for the depth of fusion into the joint.
When you have gouged deep enough, you will
C D see a very distinct line that is the joint root.
Table 17-10 gives some general setting informa-
Fig. 17-38 CAC-A torch positions for all-position gouging.
ource: American Welding Society, C5.3-91, Air Carbon Arc Gouging and Cutting,
S tion. Table 17-12, p.546, covers troubleshooting
p. 6 and 7, figs. 6 through9 issues.

10

CAC-A 11/2

31/8

11/2

1/4 11/2 10
2 CAC-a 5/16 Carbon Steel
Electrode Plate
No. Part No. Name Size Matl. Spec.

Tolerance-fractional Limits 1/16

5/16
Weld this square groove butt joint with as large a diameter
E-7018 electrode that is available in the 1G position. Turn
5/16 the joint over and backgouge to sound metal.

No Scale Flat 17-J6

Scale Postion of Welding Part Number
and Gouging

Fig. 17-39 Job 17-J6.

544 Chapter 17 Arc Cutting Principles and Arc Cutting Practice: Jobs 17-J1J7
 Table 17-10 CAC-A Settings for Gouging

Desired DCEP Polarity and

Groove Travel Speed Power Data Compressed Air
Electrode Diameter Depth (in./min) Amperes Volts ft /min
3
p.s.i.
5
16 1
8 65 400 42 30 60
5
16 16
3
45 400 42 30 60
5
16 1
4 36 400 42 30 60
5
16 16
5
33 400 42 30 60
1
4 NA NA 300400 42 30 60

Source: American Welding Society

Begin gouge on one end.

Look for line which is the
joint root.
Fillet Weld to be removed

4 6 1/4 Carbon 1/4 11/2 10 Steel

Electrode Plate 1/4 31/4 10
No. Part No. Name Size Matl. Spec.

Tolerance-fractional Limits 1/8

Part Name Type of Weld Fillet and Gouge

No Scale Flat 17-J7

Scale Postion of Welding Part Number

Fig. 17-40 Job 17-J7.

Shutting Down the CAC-A Equipment
1. Turn off the air supply by using the torch valve. Allow
enough airflow time to help cool the carbon electrode.
Do not let the electrode come into contact with the
workpiece until the power source is turned off.
2. Turn off the power source.
3. Turn off the main air supply.
4. Remove the carbon electrode from the holder. Place it
in its proper storage area after it has cooled.
5. Disconnect the air supply and power cable to the
torch. Disconnect the workpiece connection.
6. Wrap up the work and electrode cables. Wrap up the
air hose and store. Place the carbon air arc torch in
proper storage.
7. Mark on hot metal with HOT.
8. Return all unused carbon electrodes to proper
storage.
9. Dispose of all dross, used electrodes, and scrap
metal.
10. Turn off the main power to both the power source
and air compressor.
11. Conduct a fire watch for smoldering combustibles a
minimum of one hour after work stoppage.

Arc Cutting Principles and Arc Cutting Practice: Jobs 17-J1J7 Chapter 17 545
 Table 17-11 Job Outline: Air Carbon Arc Cutting: Jobs 17-J6J7

Electrical
Requirements Minimum Air AWS
Job Carbon DCEP Pressure and S.E.N.S.E.
Number Type of Job Material1 Thickness (in.) Diameter Amperes Volts Flow Rate Text Reference Reference
17-J6 Gouge Carbon 1
4 5
16 400 42 60 p.s.i. @ 561 Entry level,
U-groove steel 30 ft3/min advanced
level1
17-J7 Weld Carbon 1
4 1
4 350 42 60 p.s.i. @ 562 Entry level,
removal steel 30 ft3/min advanced
level1

Practice is required on pipe and plate for the advanced level.

1

Table 17-12 Troubleshooting CAC-A

Problem
Carbon deposits at beginning of groove
Unsteady arc, requiring slow travel speed even on shallow
grooves
Erratic groove with arc wandering and electrode heating
rapidly
Erratic arc action, with arc going on and off with rough
groove surface
Carbon deposits at various locations in the groove
Irregular groove depth
Dross adhering to the edges of the groove
Correction
Turn on air jet before starting arc; make sure air jet is between electrode and
workpiece.
There is insufficient amperage for the electrode diameter. Use a larger power
source or, if not available, smaller diameter carbon.
The current and polarity must be DCEP.
Speed up the rate of travel. This is a very fast process and you must keep the arc
length short. Keep in mind that the weld pool is constantly being blown away with
the high volume of air pressure. Position yourself to be able to freely move to keep
up with the metal removal.
The carbon electrode was shorted out on the workpiece and/or travel speed
was too fast.
Keep your travel speed, arc length, and electrode angle steady.
There is not enough air pressure or flow rate. The volume of the air is very
important. Make sure at least a minimum of 38 in. inside diameter hoses are
used.
No restriction should exist in the air lines.

CHAPTER 17 REVIEW

Multiple Choice 2. Arc cutting is done with the heat of an electric arc
and which of the following? (Obj. 17-1)
Choose the letter of the correct answer.
a. Oxygen
1. Arc cutting can be used on which of the following b. Compressed air
metals? (Obj. 17-1) c. Inert gas
a. Cast iron d. All of these can be used
b. Aluminum
3. The basic principle of PAC is that an electric
c. Titanium
arc constricted through a small nozzle opening
d. All of these

546 Chapter 17 Arc Cutting Principles and Arc Cutting Practice: Jobs 17-J1J7
 increases the arc temperature to approximately 11. When CAC-A is being done, when should the air be
_______F. (Obj. 17-2) turned on? (Obj. 17-3)
a. 250,000 a. When the arc is struck and a weld pool has
b. 25,000 formed
c. 2,500 b. When the cut is complete to cool the plate down
d. It is too hot to measure c. Never turn air on with this process because the
4. The arc that starts when the trigger on a plasma arc heat of the arc melts the plate
torch is depressed is called the _______. (Obj. 17-2) d. When you are ready to start the arc so that car-
a. Starter arc bon deposits are not left on the plate
b. Main arc 12. The fine lines left on a cut surface are called _______.
c. Cutting arc (Obj. 17-4)
d. Pilot arc a. Drag lines
5. Plasma is considered _______. (Obj. 17-2) b. Kerf lines
a. The fourth state of matter c. Dross lines
b. A rare earth element d. Cut lines
c. An ionized gas 13. If one side of the PAC has a slight bevel of 4 to 6,
d. Both a and c this is considered _______. (Obj. 17-4)
6. Which of the following electrode angles are used for a. A poor cut and the torch angle needs to be held
CAC-A? (Obj. 17-3) at 90
a. Push b. Normal for this process
b. Drag c. A poor cut and faster travel speed is required
c. Work d. A poor cut and the power setting on the machine
d. Backhand needs to be reduced
7. Which of the following will control the depth of a 14. The CAC-A should be _______. (Obj. 17-4)
CAC-A groove? (Obj. 17-3) a. Clean
a. Electrode angle b. Smooth
b. Travel speed c. Free of dross
c. Current d. All of these
d. All of these 15. If the bottom of a CAC-A groove is excessively V
8. To change the shape of the groove from a U to a shaped, what can be done? (Obj. 17-4)
V with the CAC-A process, which control will a. Decrease torch angle
have the most effect? (Obj. 17-3) b. Increase torch angle
a. Air pressure c. Decrease current by 15 percent
b. Current level d. Increase current by 15 percent
c. Electrode angle 16. Which of the following is not part of setting up and
d. Travel speed using PAC equipment? (Obj. 17-5)
9. The carbon electrode should extend beyond the a. Connect the power source to primary power
torch _______ inches. (Obj. 17-3) b. Check the torch, air (plasma gas) settings, and
a. 12 to 112 work clamp connections
b. 112 to 7 c. Turn on and set the fuel gas flow rate
c. 7 to 10 d. Check the torch tip, electrode, and shield cup
d. It is gripped on the very end of the electrode and 17. Which of the following is not part of setting up and
used down to nothing using CAC-A equipment? (Obj. 17-5)
10. Where should the air jet ports on the CAC-A torch a. Connect the power source to primary power and
be located? (Obj. 17-3) make sure the power is turned off
a. Between the electrode and the work b. Connect the electrical power and air supply to
b. On top of the electrode away from the work the torch
c. Alongside the electrode c. Attach the work clamp and cable to the power
d. It does not matter where they are located be- source using DCEP
cause the air is forced through the electrode d. Select the proper size and shape of metallic
center electrode

Arc Cutting Principles and Arc Cutting Practice: Jobs 17-J1J7 Chapter 17 547
18. PAC with too high a rate of travel speed will
cause_______. (Obj. 17-6)
a. The lines along the edge of the cut to be very
curved
b. Dross on the bottom of the cut to be hard to
remove
c. The part to not be completely cut through
d. All of these
19. If while CAC-A gouging the arc action is erratic
and goes on and off with a rough groove surface,
which of the following is most likely to be the cause
of this problem? (Obj. 17-6)
a. Air was not turned on prior to starting the arc
b. There is insufficient amperage
c. The current and polarity are wrong
d. The travel speed is too slow
20. If while CAC-A gouging the dross adheres to
the cut, what corrective actions should you take?
(Obj. 17-6)
a. Slow down; the travel speed is too fast
b. Increase the amperage; you are cutting too cold
c. Increase the air pressure and make sure the hose
is large enough to get the proper flow rate
d. Correct the electrode angle; it is too steep or
too flat
Review Questions
Write the answers in your own words.
21. What makes plasma arc cutting different from
oxyfuel cutting? (Obj. 17-2)
22. List seven advantages of PAC. (Obj. 17-1)
23. A tremendous amount of noise and fumes are
generated with high-powered mechanized plasma
arc cutting. What can be done to overcome this?
(Obj. 17-1)
24. List some inspection points and considerations for
proper maintenance of a PAC torch. (Obj.17-5)
25. List the proper cutting procedure and technique
for making an air carbon arc gouge with a 516-inch
carbon to a depth of 316 inch. (Obj. 17-3)

INTERNET ACTIVITIES

Internet Activity A
Search any one of the Web pages of major plasma arc cutting equipment manufac-
turers and make a report to your instructor on what are the most recent equipment
innovations.
Internet Activity B
Using your favorite search engines check out the various types of plasma and
shielding gases that are recommended for the PAC process.

548 Chapter 17 Arc Cutting Principles and Arc Cutting Practice: Jobs 17-J1J7