COPPER COATED
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AIR CARBON ARC GOUGING CARBONS
AIR CARBON ARC GOUGING DATA:
The air carbon arc process is flexible, efficient, and cost effective on practically any metal; carbon steel, stainless steel and other ferrous alloys; gray, malleable and ductile cast iron; aluminum; nickel; copper alloys and other nonferrous metals. Single-phase machines with low open-circuit voltage may not work for air carbon arc gouging (CAC-A). However, any three-phase welding power source of sufficient capacity may be used for air carbon arc gouging. The arc voltage used in air carbon arc gouging and cutting ranges from a low of 35 to a high of 56 volts; thus the open-circuit voltage should be at least 60 volts. The actual arc voltage is governed by arc length and the type of gouging. For most applications CAC-A is used with DCEP (reverse polarity). The electrode should extend at most 7 inches from the gouging torch with the air jet between the electrode and work piece. A minimum extension of 2” should be used to prevent damage to the torch parts. Normal compressed air pressures for CAC-A range between 80 psi and 100 psi at the torch; higher pressures may be used, but they don’t remove metal more efficiently. Use 60 psi (413.7 kPa) with the light-duty manual torch. The air hose supplying air to the torch body should have an inside diameter of at least 3/8” (6.4 mm).
SUGGESTED CURRENT RANGES FOR COMMONLY USED ELECTRODE TYPES AND SIZES
ELECTRODE DIAMETER DC ELECTRODE WITH DCEP AC ELECTRODE WITH AC AC ELECTRODE WITH DCEN In. mm Min Amps Max Amps Min Amps Max Amps Min Amps Max Amps 1/8 3.2 60 90 – – – – 5/32 4.0 90 150 – – – – 3/16 4.8 200 250 200 250 150 180 ¼ 6.4 300 400 300 400 200 250 5/16 7.9 350 450 – – – – 3/8 9.5 450 600 350 450 300 400 ½ 12.7 800 1000 – – – – 5/8 15.9 1000 1250 – – – – ¾ 19.1 1250 1600 – – – – 1 25.4 1600 2200 – – – –
RECOMMENDED MINIMUM AIR REQUIREMENTS
Recommended Compressor Rating
Air Pressure Air consumption Intermittent Use Continuous Use ASME Receiver Sz
Type of Torch psi kPa cfm L/min hp kW hp kW gal litres Light Duty (2) 40 280 8 227 .5 0.4 1.5 1.1 60 227 General Duty (2) 80 550 25 708 5.0 3.7 7.5 5.6 80 303 Multipurpose (3) 80 550 33 934 7.5 5.6 10 7.5 80 303 Automatic (4) 60 414 46 1303 15 11.2 80 303
1. Pressure while torch is in operation.
2. Accommodates flat electrodes.
3. Generally considered a foundry torch
4. Requires some kind of mechanical manipulation.
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PERMISSIBLE NOISE EXPOSURE
Ear protection is recommended when noise from the air carbon arc process exceeds permissible levels as listed in OSHA 1910.95
Duration Per Day Sound Level DBA (in hours) Slow Response 8 90 6 92 4 95 3 97 2 100 1 ½ 102 1 105 ¼ or less 115
BLUE DEMON WELDING PRODUCTS
Air carbon arc cutting, also referred to as metal arc gouging, and previously as air arc cutting,[1] is an arc cutting process where metal is cut and melted by the heat of a carbon arc. Molten metal is then removed by a blast of air. It employs a consumable carbon or graphite electrode to melt the material, which is then blown away by an air jet.
This process is useful for cutting a variety of materials, but it is most often used for cutting and gouging aluminum, copper, iron, magnesium, and carbon and stainless steel. Because the metal is blown away by the air jet, it does not need to be oxidized. This process differs from plasma cutting operations because in air carbon cutting an open, unconstricted arc is used, and the arc operates separately from the air jet.
Air pressure for the jet usually varies from 60 to 100 psi (4-7 bar). The carbon electrode can be worn away by oxidation due to heat buildup. This can be reduced by coating the electrodes with copper.
As the sharpened carbon electrode is drawn along the metal, an arc forms and melts the metal. The air jet is used to blow away molten material. This can be dangerous, as the molten material can be blown substantial distances.[2] The process is also very noisy. Metal removal is rapid, and when properly done, a smooth half-cylindrical cavity is created.[3]
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