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AIR CARBON ARC GOUGING

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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

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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

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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 side

walls. 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 Carbon
Current A dimensions Gouging
Electrode electrode
Note: DC speed
diameter (mm) Depth Width consumed
electrode (mm/min)
(mm) (mm) (mm/min)

Manual 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

13.0 550 12-13 18-19 76 508

Automatic 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

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

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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.

For more information please email:

contactus@twi.co.uk

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TWI Ltd (Head Office)

Granta Park, Great Abington, Cambridge, CB21 6AL, UK

+44(0)1223 899000

contactus@twi.co.uk

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