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The Full Guide to Oxy-Fuel Cutting

The Full Guide to Oxy-Fuel Cutting

Oxy-fuel cutting is a widely used process in the welding and fabrication industries, known for its versatility and ability to cut through thick steel with precision. Whether you're a beginner or a seasoned welder, understanding the fundamentals of oxy-fuel cutting will help you achieve clean, efficient cuts while ensuring safety in the workshop. In this guide, we'll walk you through the key components, setup, operation, and safety precautions of oxy-fuel cutting. 

What Is Oxy-Fuel Cutting?

Oxy-fuel cutting, also known as oxyacetylene cutting, uses a combination of oxygen and a fuel gas (typically acetylene, propane, or natural gas) to heat metal to its ignition temperature. Once the metal reaches a molten state, a high-pressure stream of pure oxygen is directed at the metal, causing it to oxidize and blow away, resulting in a clean cut.

Essential Equipment for Oxy-Fuel Cutting

To get started with oxy-fuel cutting, you'll need the following equipment:

Oxygen and Fuel Gas Cylinders -- Oxygen is stored in high-pressure cylinders, while acetylene or other fuel gases are kept in lower-pressure cylinders.

Regulators -- These control the pressure of gases flowing from the cylinders.

Hoses and Fittings -- Color-coded hoses (red for acetylene and green for oxygen) connect the regulators to the torch.

Cutting Torch -- This handheld tool mixes and directs gases to the cutting tip.

Cutting Tips -- These come in different sizes, depending on the thickness of the material being cut.

Spark Lighter or Striker -- Used to ignite the flame safely.

Personal Protective Equipment (PPE) -- Includes safety glasses, gloves, flame-resistant clothing, and a welding helmet or face shield.

 

Setting Up Your Oxy-Fuel Cutting System

Step 1: Inspect and Assemble Equipment

Before beginning, ensure all equipment is in good condition. Check hoses for leaks, confirm cylinder connections are secure, and inspect the cutting tip for obstructions.

Step 2: Open the Cylinders

  1. Open the oxygen cylinder valve slowly and fully.
  2. Open the fuel gas cylinder valve about 1/4 to 1/2 turn to allow for quick shutoff in case of emergency.

Step 3: Adjust the Pressure

Refer to manufacturer guidelines for the appropriate pressure settings based on your fuel type and material thickness. Adjust the regulators accordingly.

Step 4: Light the Torch

  1. Open the fuel valve slightly and ignite the gas using a spark lighter.
  2. Slowly open the oxygen valve to achieve a neutral flame (a balanced mix of oxygen and fuel gas). 

Step 5: Preheat the Metal

Position the cutting tip about 1/8 inch from the metal surface and heat the material until it turns cherry red.

Step 6: Initiate the Cut

Once the metal is preheated, press the cutting oxygen lever to release a high-pressure stream of oxygen. Move the torch steadily along the cutting line.

Tips for Achieving a Clean Cut

  • Maintain a consistent travel speed to avoid excessive slag.
  • Keep the cutting tip at a steady height above the workpiece.
  • Use the correct cutting tip size for the material thickness.
  • Avoid excessive oxygen pressure, as it can cause rough edges.
  • Ensure your metal surface is free of rust, paint, and other contaminants before cutting.

Safety Precautions

Working with oxy-fuel cutting systems requires strict adherence to safety guidelines:

  • Always use flashback arrestors to prevent backflow of gases.
  • Store oxygen and fuel gas cylinders upright and secured.
  • Never use oil or grease on oxy-fuel equipment, as this can cause combustion.
  • Perform leak tests on hoses and fittings using soapy water. 
  • Work in a well-ventilated area to prevent gas accumulation.
  • Wear proper PPE to protect against sparks and heat.

Common Applications of Oxy-Fuel Cutting

Oxy-fuel cutting is widely used in various industries, including: 

  • Metal fabrication and manufacturing
  • Shipbuilding and automotive repair
  • Demolition and scrap metal processing
  • Pipeline and structural steel cutting

Oxy-fuel cutting is an essential skill for welders and fabricators, offering a reliable method for cutting steel and other ferrous metals. By following proper setup procedures, safety protocols, and best practices, you can achieve precise, high-quality cuts while maintaining a safe working environment. 

For all your welding and cutting equipment needs, reach out to Baker's Gas and Welding by calling 877-930-5690 or emailing support@bakersgas.com. Our team is here to help you find the best tools and supplies for your next project!

Drew A.

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