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AIR CARBON ARC GOUGING DATA

COPPER COATED AIR CARBON ARC GOUGING CARBONS

FROM WELDING MATERIAL SALES (BLUE DEMON):

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.

 

 

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