AWS Abbreviations

Oxyfuel Cutting - OFC

Oxyacetylene Cutting - OFC-A

Oxyfuel Cutting - Process and Fuel Gases

The oxyfuel process is the most widely applied industrial thermal cutting process because it can
cut thicknesses from 0.5mm to 250mm (10 inch), the equipment is low cost and can be used
manually or mechanised. There are several fuel gas and nozzle design options that can
significantly enhance performance in terms of cut quality and cutting speed.
Process Fundamentals
The cutting process is illustrated in Fig. 1. Basically, a mixture of oxygen and the fuel gas is used
to preheat the metal to its 'ignition' temperature which, for steel, is 700°C - 900°C (bright red
heat) but well below its melting point. A jet of pure oxygen is then directed into the preheated
area instigating a vigorous exothermic chemical reaction between the oxygen and the metal to
form iron oxide or slag. The oxygen jet blows away the slag enabling the jet to pierce through the
material and continue to cut through the material.

Fig.1. Diagram of oxyacetylene cutting process

There are four basic requirements for oxy-fuel cutting:

1. The ignition temperature of the material must be lower than its melting point otherwise the
material would melt and flow away before cutting could take place
2. The oxide melting point must be lower than that of the surrounding material so that it can
be mechanically blown away by the oxygen jet
3. The oxidation reaction between the oxygen jet and the metal must be sufficient to maintain
the ignition temperature
 4. A minimum of gaseous reaction products should be produced so as not to dilute the
cutting oxygen
As stainless steel, cast iron and non-ferrous metals form refractory oxides i.e. the oxide melting
point is higher than the material, powder must be injected into the flame to form a low melting
point, fluid slag.

Purity of Oxygen
The cutting speed and cut edge quality are primarily determined by the purity of the oxygen
stream. Thus, nozzle design plays a significant role in protecting the oxygen stream from air
entrainment. The purity of oxygen should be at least 99.5%. A decrease in purity of 1% will
typically reduce the cutting speed by 25% and increase the gas consumption by 25%.
Choice of Fuel Gas
Fuel gas combustion occurs in two distinct zones. In the inner cone or primary flame, the fuel gas
combines with oxygen to form carbon monoxide and hydrogen which for acetylene, the reaction
is given by
2C2H2 + 2O2 → 4CO + 2H2
Combustion also continues in the secondary or outer zone of the flame with oxygen being
supplied from the air.
4CO+2H2 +3O2 → 4CO2 +2H2O
Thus, fuel gases are characterised by their
1. Flame temperature - the hottest part of the flame is at the tip of the primary flame (inner
cone)
2. Fuel gas to oxygen ratio - the amount of fuel gas required for combustion but this will vary
according to whether the flame is neutral, oxidizing or reducing
3. Heat of combustion - heat of combustion is greater in the outer part of the flame
The five most commonly used fuel gases are acetylene, propane, propylene, natural gas,
methylacetylene propadiene also called MAPP. The properties of the gases are given in the Table
below. The relative performance of the fuel gases in terms of pierce time, cutting speed and cut
edge quality is determined by the flame temperature and heat distribution within the inner and out
flame cones.
Acetylene
Acetylene produces the highest flame temperature of all the fuel gases. The maximum flame
temperature for acetylene (in oxygen) is approximately 3,160°C compared with a maximum
temperature of 2,828°C with propane. The hotter flame produces more rapid piercing of the
materials with the pierce time being typically one third that produced with propane.
The higher flame speed (7.4m/s compared with 3.3m/s for propane) and the higher calorific
value of the primary flame (inner cone) (18,890kJ/m3 compared with 10,433 kJ/m3 for propane)
produce a more intense flame at the surface of the metal reducing the width of the Heat Affected
Zone (HAZ) and the degree of distortion.
Propane
Propane produces a lower flame temperature than acetylene (the maximum flame temperature in
oxygen is 2,828°C compared with 3,160°C for acetylene). It has a greater total heat of combustion
than acetylene but the heat is generated mostly in the outer cone (see Table). The characteristic
appearance of the flames for acetylene and propane are shown in Figs.2 and 3 where the propane
flame appears to be less focused. Consequently, piercing is much slower but as the burning and
slag formation are effected by the oxygen jet, cutting speeds are about the same as for acetylene.
Propane has a greater stoichiometric oxygen requirement than acetylene; for the maximum flame
temperature in oxygen, the ratio of the volume of oxygen to fuel gas are 1.2 to 1 for acetylene and
4.3 to 1 for propane.

Fig.2. Oxyacetylene gas jet and nozzle design

Fig.3. Propane gas jet and nozzle design

MAPP
MAPP gas is a mixture of various hydrocarbons, principally, methylacetylene and propadiene. It
produces a relatively hot flame (2,976°C) with a high heat release in the primary flame (inner
cone) (15,445kJ/m3), less than for acetylene (18,890kJm3) but much higher than for propane
(10,433kJm3). The secondary flame (outer cone) also gives off a high heat release, similar to
propane and natural gas. The combination of a lower flame temperature, more distributed heat
source and larger gas flows compared with acetylene results in a substantially slower pierce time.
As MAPP gas can be used at a higher pressure than acetylene, it can be used for underwater
cutting in deep water as it is less likely to dissociate into its components of carbon and hydrogen
which are explosive.
Propylene
Propylene is a liquid petroleum gas (LPG) product and has a similar flame temperature to MAPP
(2896°C compared to 2,976°C for MAPP); it is hotter than propane, but not as hot as acetylene.
It gives off a high heat release in the outer cone (72,000kJ/m3) but, like propane, it has the
disadvantage of having a high stoichiometric fuel gas requirement (oxygen to fuel gas ratio of
approximately 3.7 to 1 by volume).
Natural Gas
Natural gas has the lowest flame temperature similar to propane and the lowest total heat value of
the commonly used fuel gases, e.g. for the inner flame 1,490kJ/m3 compared with
18,890kJ/m3 for acetylene. Consequently, natural gas is the slowest for piercing.

Table : Fuel Gas Characteristics

Maximum Flame Oxygen to fuel gas Heat distribution
Fuel Gas
Temperature °C Ratio (vol) kJ/m3
Primary Secondary
Acetylene 3,160 1.2:1 18,890 35,882
Propane 2,828 4.3:1 10,433 85,325
MAPP 2,976 3.3:1 15,445 56,431
Propylene 2,896 3.7:1 16,000 72,000
Hydrogen 2,856 0.42:1 - -
Natural Gas 2,770 1.8:1 1,490 35,770

Theory of Oxy-Fuel Gas Cutting

Oxy-Fuel gas cutting is functional for use with low carbon and low alloy steels, with a carbon
content generally restricted to 1/10 to 3/10 of 1%. The various alloy elements found in steel
affect the ability of the oxygen to cut the metal. Elements such as manganese, silicon,
phosphorus, and sulfur have very little effect in normally found levels. Other elements such as
chromium, nickel, molybdenum, and carbon generally reduce the ability of oxygen to sever the
material up to the various limits of each.
Prior to attempting to flame cut a piece of material, you must study it and consider the elements it
contains as well as the combinations of these elements, just as you would if you studied the metal
for physical properties for heat treatment, flame hardening etc.
A cutting torch diverts the oxygen and mixes part of it with the fuel gas to create the preheat
flame, forming the ring of flame around the cutting tip. This preheat flame will reach a
temperature of 4400°F to 6000°F, depending on the fuel gas used as well as the ratio of oxygen to
fuel gas.
In order to start a chemical reaction, the metal must be raised to the kindling temperature, which
in mild carbon steel is approximately 1600°F. The autoignition temperature or kindling
point of a substance is the lowest temperature at which it spontaneously ignites in normal
atmosphere without an external source of ignition, such as a flame or spark. This temperature is
required to supply the activation energy needed for combustion. At this point the metal will reach
a bright orange color and sparks will be noticed on the top edge. When the kindling
temperature is reached, the cutting oxygen lever is opened and high purity oxygen is introduced.
As the oxygen chemically combines with the iron exothermically (exothermic reaction), the result
is generally referred to as the "cutting jet." The cutting jet is always in the center of the tip and
instantly starts a rapid oxidation of the steel through the depth of the cut. A tremendous amount
of heat is liberated when the high purity oxygen unites with the steel during this reaction.
If carried through to completion, you have three balanced chemical equations as a result of this
reaction:

Fe + O --- FeO + Heat (63,800 cal) First Reaction

3Fe + 2O2 --- Fe3O4 + Heat (267,800 cal) Second Reaction

2Fe + 3/2 O2 --- Fe2O3 + Heat (196,800 cal) Third Reaction

The third reaction occurs, to some extent, in heavier section cutting, with the first and second
predominating. Theoretically it takes 4.6 cubic feet of oxygen to oxidize one pound of steel
completely to ferrous oxide (Fe3O4). In practical cutting operations the amount of oxygen used is
less because not all of the iron is completely oxidized to ferrous oxide. This set amount of
oxygen is the constant required to flame cut metal no matter what fuel gas is used for the preheat
function.
As the iron is oxidized it starts to flow; some of the material adjacent to the iron oxides is melted
and also flows, due to the intense heat that is liberated in the chemical reaction. The removal of
all the metal is based in a large part on the velocity and coherency of the high purity oxygen
cutting jet.
Equipment Setup

Acetylene main valve should only be opened 1/2 turn, and the regulator set at 5 to 7 psi (pounds
per square inch). (If acetylene is turned up too high, it can become unstable.) For welding, the
oxygen should be set between 7 and 10 psi. For cutting the oxygen should be set between 15 and
25 psi.

Welding Head

A welding head is simple, and has two valves located near the base of the head. To use this head:
1. Turn on the Acetylene valve until you hear a slight hiss of gas from the nozzle.
2. Take your striker/lighter and light the torch.
 3. This should produce a dark red-orange flame which puts out very putrid black smoke.
4. Now, slowly turn on the valve that controls your oxygen, until you see the flame
change. Careful: too much oxygen can "bleed out" the flame -- which means the flame will
go out. In this event, turn the oxygen off and try again. The flame should be blue with a
white inside tip. The inner, white tip should measure around 3⁄8 inch (1.0 cm) long.

Cutting Head

It has a trigger, and two or three tubes going up to the nozzle.

1. First, turn the oxygen valve on the body trigger all the way on
2. Turn on the Acetylene valve until you hear a slight hiss of gas from the nozzle.
3. Take your striker/lighter and light the torch.
4. This should produce a dark red/orange flame that puts out very putrid black smoke.
5. Now, slowly turn on the valve that controls your Oxygen (there are two valves for oxygen
on a cutting head, one blocked (controlled by the trigger) and one unrestricted) until you
see the flame change.
6. The flame, when the trigger is not compressed, should be a blue flame, measuring about
two inches, with about a 1/2" bluish-yellow inner flame.
7. When the trigger is compressed, the flame will become much shorter, louder, and faster.
8. When cutting, always heat the metal up to a nice cherry red, and then press the trigger for
oxygen. Caution: Sparks will be thrown, so be aware and safe.

1. Adjust the preheating flame to neutral.

2. Hold the torch so that the cutting oxygen lever or trigger can be operated with one hand.
Use the other hand to steady and maintain the position of the torch head to the work.
3. Keep the flame at a 90 degree angle to work in the direction of travel. The inner cones of
the preheating flames should be about 1/16 in. (1.6 mm) above the end of the line to be
cut. Hold this position until the spot has been raised to a bright red heat, and then slowly
open the cutting oxygen valve.
4. If the cut has been started properly, a shower of sparks will fall from the opposite side of
the work. Move the torch at a speed which will allow the cut to continue penetrating the
work. A good cut will be

Oxy-fuel cutting is widely used for cutting steel of all shapes and sizes.
You may have heard oxy-fuel cutting described as “burning”, “torch cutting”, or “flame cutting”.
Each of these names contains an element of truth in describing the process. An oxy-
fuel cutting torch is used, it has a flame, and the steel is “burned” as it cuts. The actual chemical
process that takes place is sometimes described as “rapid rusting” of the steel. Whether you think
of it as burning or rusting, the result is similar – the steel is rapidly oxidized in a chemical reaction
that generates heat.
Here are the basics of how it all works:
Step 1: Preheat
Before you can start cutting the steel, it has to be heated up to its kindling temperature, about
1800°F. At this temperature, the steel readily reacts with oxygen. The heat is provided by the
preheat flames from an oxy-fuel torch. Inside the torch a fuel gas is mixed with oxygen to create a
highly flammable mixture. A nozzle has multiple holes arranged in a circular pattern to focus the
flammable gas mixture into multiple little jets. The fuel-oxygen mixture is ignited outside of the
nozzle, and the preheat flames form just outside the nozzle tip.
Commonly used fuel gases include acetylene, propane, natural gas, and a few other mixed gases.
By adjusting the fuel-to-oxygen ratio, the flame is adjusted to produce the highest possible
temperature in the smallest possible flame. This concentrates the heat in a small area on the
surface of the steel plate.
Step 2: Piercing
Once the surface or edge of the plate has reached kindling temperature, a jet of pure oxygen is
turned on to begin piercing through the plate. This is called the “cutting oxygen”, and the jet is
formed by a single bore in the center of the nozzle. As the cutting oxygen stream hits the pre-
heated steel, the rapid oxidation process begins. This is when the real fun begins. The oxidation
process is referred to as an exothermic reaction – it gives off more heat than it takes to get
started. The oxidized steel takes the form of molten slag, and the molten slag has to get out of the
way so the oxygen stream can “pierce” all the way through the plate. Depending on how thick the
plate is, this can take anywhere from a fraction of a second up to several seconds. During this
time, the cutting oxygen stream is pushing deeper and deeper into the plate, and the molten slag is
being blown out of the pierce hole. This can result in a massive geyser of molten steel, or if done
properly, a small puddle of slag on top of the plate.
Step 3: Cutting
Once the cutting oxygen stream has made its way all the way through the plate, the torch can start
moving at a constant speed, forming a continuous cut. The molten slag formed during this phase
is blown out the bottom of the plate. The heat given off by the chemical reaction between the
oxygen and the steel preheats the plate just in front of the cut, but not reliably enough to cut
without the preheat flames. So the preheat flames stay on throughout the cut, adding heat to the
plate as the torch moves.
Those are the basics. But there are lots of other factors affect the quality of the cut edge,
including speed, cut oxygen pressure, preheat flame adjustment, cutting height, plate temperature,
etc.
So why doesn’t this process work on any metal? When most metals are oxidized, they form an
oxide that has a higher melting temperature than original metal. This forms a protective crust that
prevents further oxidation. Only low carbon steel and some low alloys have oxides with a lower
melting point than the base metal, so they can be cut with the oxy-fuel process.
How to Properly Light, Adjust and Shut Down an Oxyacetylene Torch
Lighting, adjusting and shutting down an oxygen-acetylene torch is easy – especially when
following the proper procedures. In addition to these easy to follow instructions, you must always
be sure to follow the torch manufacturer's operating procedures.
First - before you attempt to light the torch follow these checks:

1. Make sure regulator pressure adjustment screws are backed out!

2. Make sure torch valves are closed!
3. Stand away from front of regulator
4. Separately and slowly open the oxygen and acetylene cylinder valves
5. Adjust regulator p/a screws to tip pressure settings
6. Open/close torch valves separately and fine tune pressure settings on regulators
7. Depress cutting lever and adjust pressure if necessary

Lighting and adjusting the torch (with a positive/equal pressure mixer):

1. Separately purge both oxygen and fuel gas lines

2. Open fuel gas valve 1/2 turn
3. Ignite flame with striker
4. Increase fuel gas flow until flame leaves end of tip and no smoke is present
5. Decrease until flame goes back to tip
6. Open oxygen valve and adjust to neutral flame
7. Depress oxygen lever and make necessary adjustments

Shutting down the torch (with a positive/equal pressure mixer):

1. Close oxygen torch valve

2. Close fuel gas torch valve

If the torch/regulators and gases are done being used for a while, follow these procedures:

1. Close oxygen and fuel gas cylinder valves

2. Separately purge oxygen and fuel gas lines
3. Make sure all regulator gauges read 0
4. Back out regulator pressure adjustment screws!
5. If you are using in a commercial environment, report any damage, etc. to your supervisor