Thermal Gouging

Thermal gouging is an essential part of welding fabrication. Used for rapid removal of unwanted metal, the material is
locally heated and molten metal ejected - usually by blowing it away. Normal oxyfuel gas or arc processes can be used to
produce rapid melting and metal removal. However, to produce a groove of specific dimensions, particularly regarding
depth and width, the welder must exercise careful control of the gouging operation. If this does not happen, an erratic
and badly-serrated groove will result.

Thermal processes, operations and metals which may be gouged or otherwise shaped:

Thermal Process operations

Metals
process
Primary Secondary
Grooving Low carbon steels, carbon manganese steels (structural), pressure vessel steels
Oxyfuel
Gouging Washing (carbon not over 0.35%), low alloy steels (less than 5%Cr) cast iron (if preheated
gas flame
Chamfering to 400-450 deg.C)
Manual Grooving Low carbon steels carbon manganese steels (structural), pressure vessel steels, low
Gouging
metal arc Chamfering alloy steels, stainless steels, cast iron, nickel-based alloys
Low carbon steels carbon manganese steels (structural), pressure vessel steels, low
Air carbon Grooving
Gouging and high alloy steels, cast iron, nickel-based alloys, copper and copper alloys,
arc Chamfering
copper/nickel alloys, aluminium
Chamfering
Plasma arc Gouging Grooving Aluminium, stainless steels
Washing

I
Note: All processes are capable of cutting/severing operations. Preheat may or may not be required on some metals prior
to gouging

1. Safety

T W
It should be emphasised that because gouging relies on molten metal being forcibly ejected, often over quite large
distances, the welder must take appropriate precautions to protect himself, other workers and his equipment. Sensible
precautions include protective clothing for the welder, shielding inside a specially-enclosed booth or screens, adequate
fume extraction, and removal of all combustible material from the immediate area.

2. Industrial Applications
Thermal gouging was developed primarily for removal of metal from the reverse side of welded joints, removal of tack
welds, temporary welds, and weld imperfections. Figure 1 illustrates the value of typical back-gouging applications carried
out on arc welded joints., while Fig. 2 shows imperfection removal in preparation for weld repair.

Fig.1 Typical back-gouging applications carried out on arc welded joints

TWI JOB KNOWLEDGE FOR WELDERS 1-2

 Fig. 2 Imperfection removal in preparation for weld repair

The gouging process has proved to be so successful that it is used for a wide spectrum of applications in engineering
industries:

• repair and maintenance of structures - bridges, earth-moving equipment, mining machinery, railway rolling stock,
ships, offshore rigs, piping and storage tanks
• removal of cracks and imperfections - blow holes and sand traps in both ferrous and non-ferrous forgings and
castings
• preparation of plate edges for welding
• removal of surplus metal - strongbacks, lifting lugs and riser pads and fins on castings, excess weld bead profiles,
temporary backing strips, rivet washing and shaping operations demolition of welded and unwelded structures -
site work

Thermal gouging is also suitable for efficient removal of temporary welded attachments such as brackets, strongbacks,
lifting lugs and redundant tack welds, during various stages of fabrication and construction work.

3. Gouging Processes

I
Gouging operations can be carried out using the following thermal processes:

W
• oxyfuel gas flame
• manual metal arc
• air carbon arc

T
• plasma arc

TWI JOB KNOWLEDGE FOR WELDERS 2-2