BACK GOUGING PROCEDURE

06-Jan16

For
Review
&
Approva
l

Mahesh
QA Engineer

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Re
v

Date

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FERRITE TEST PROCEDURE

Table of Contents
1. SCOPE...................................................................................................3
2. REFERENCES........................................................................................3
3. PROCEDURE.........................................................................................3
3.1ELECTRODES........................................................................................4
3.2OPERATING TECHNIQUES...................................................................4
3.3INSPECTION.........................................................................................8

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1. SCOPE
The purpose of this procedure is to set guidelines for excavation
and cutting with gouging process. This procedure describes the
recommended practices of Carbon Arc Gouging (CAG) and cutting,
and provides a general description of components used for the
process, and process consumables.
2. REFERENCES
AWS D1.1: 2015 - Structural Welding Code Steel
AWS C5.3: 2000 - Recommended Practice for Air Carbon Arc
Gouging and Cutting
3. PROCEDURE
The CAG process requires a welding power source, a source of
compressed air, carbon electrode, and cutting torch. Compressed
air is introduced to blow away the molten metal. Figure 1 shows the
typical arrangement for using this process.
CAG is used with DCEP (reverse polarity). The electrode should
have a maximum extension of 180 mm from the cutting torch,
with the air jet between the electrode and the workpiece. Although
there is no minimum extension, care should be taken to prevent
damage to the torch. Therefore 38 to 51 mm minimum extension is
recommended. Progression should only be in the direction of air
flow. The electrode push angle will vary, depending on the
operation being performed. The cutter should maintain the correct
arc length to allow the air jet to properly remove the molten metal
(see Figure 2).
Gouging process shall be done by skill person.
Figure 1 - Typical Arrangement for the Carbon Arc Gouging (CAG)
Figure 2 - How a Standard CAG Torch Works
3.1 ELECTRODES
There are three basic types of electrodes:
a. DC copper coated electrodes. This type is most widely used
because of its comparatively long electrode life, stable arc
characteristics, and groove uniformity. These electrodes are
available in the following diameters: 3, 4, 5, 6, 8, 10, 12, 16 and 19
mm. The copper coating improves electrical conductivity providing
more efficient, cooler operation and helps maintain electrode
diameter at the point of the arc.
b. DC uncoated electrodes. This type has limited use. These

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electrodes are generally used in diameters of less than 10 mm.

During cutting these electrodes are consumed more rapidly than
the coated electrodes. They are manufactured the same as the
coated electrodes without the copper coating.
c. AC copper coated electrodes. These electrodes are made from
a special mixture of carbon and graphite with a suitable binder.
Rare-earth materials are incorporated to provide arc stabilization
for cutting with an alternating current. These electrodes, coated
with a controlled thickness of copper.
3.2 OPERATING TECHNIQUES
a. Gouging. Table 1 shows suggested current ranges for various
electrode types and sizes. The electrode is gripped, so that a
maximum of 180 mm extends from the cutting torch. The air jet
should be turned on before striking the arc, and the cutting torch
should be held as shown in Figure 3. The torch should always be
operated using the forehand technique, i.e., the electrode and air
jet pointed in the direction of travel. Under proper operating
conditions, the air jet is expected to sweep beneath the electrode
end and remove all molten metal.
The steadiness of progression controls the smoothness of the
resulting cut surface.
Figure 3- Flat Gouging Position

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Table 1 - Suggested Current Ranges for Commonly Used Electrode Types

and Sizes
Electrode
Diameter
(mm)
3

DCEP
Polarity
(amperes)
30 60

AC
Electrode
(amperes)

90 150

200 250

200 250

300 400

300 400

350 450

325 425

10

450 600

350 450

13

800 1000

500 600

16

1000 1250

19

1250 1600

25

1600 2200

For gouging in the vertical position, the cutting torch should be

held as shown in Figure 4. Gouging should be done in a downhill
direction, which permits gravity to assist in removing the molten
metal.
Gouging in the horizontal position may be done either to the right
or to the left, but always with forehand gouging. In gouging to the
left, the cutting torch should be held as shown in Figure 5. In
gouging to the right, the cutting torch will be reversed to locate the
air jet behind the electrode.
When gouging in the overhead position, the electrode and torch
should be held at an angle that will prevent molten metal from
dripping on the cutter's glove, as shown in Figure 6.

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The depth of the groove produced is controlled by the travel speed.

Grooves up to 25 mm deep may be made. Slow travel speeds
produce a deep groove. Fast speeds will produce shallow grooves.
The width of the groove is determined by the size of the electrode
used and is usually about 3 mm wider than the electrode diameter.
Wider grooves may be made with an electrode that is oscillated
with a circular or weave motion.
When gouging, a push angle of 65 degrees from the surface of the
workpiece is used for most applications. A steady rest is
recommended in gouging to ensure a smoothly gouged surface. It
is particularly advantageous for use in the overhead position.

Figure 4 - Vertical Position Gouging

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Figure 5 - Horizontal Position Gouging

Figure 6 - Overhead Position Gouging

b. Cutting. Figure 7 shows the electrode in position for cutting. In
general, the cutting technique is the same as for gouging, except
that the electrode is held at a steeper angle; that is, with a push
angle between 10 and 20 degrees.
With the electrode in this position, the metal may then be cut
by moving the arc up and down through the metal with a
sawing motion.

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Figure 7 Cutting with CAG

3.3 INSPECTION
The free carbon particles are rapidly absorbed by the melted base
metal. Increased carbon can lead to increased hardness and
possible cracking. Since this absorption cannot be avoided, to
avoid difficulties with carburized metal it is important that all
carburized molten metal be removed from the cut surface. Thus,
gouging area shall be cleaned by grinding and brushing. After
grinding, these areas shall be inspected visually for recognize
removal all carburized metal.
Following grinding, the preparation shall be fully inspected visually
before the commencement of welding. Where there are visual
indications, PT or MPI shall be applied to ensure that the gouging
areas are free from defects before welding.

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