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Back Gouging Procedure
Back Gouging Procedure
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Re Date Issue Prepared By Reviewed & Reviewed &
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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)
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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.
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Table 1 - Suggested Current Ranges for Commonly Used Electrode Types
and Sizes
Electrode DCEP AC
Diameter Polarity Electrode
(mm)
3 (amperes)
30 – 60 (amperes)
4 90 – 150
5 200 – 250 200 – 250
6 300 – 400 300 – 400
8 350 – 450 325 – 425
10 450 – 600 350 – 450
13 800 – 1000 500 – 600
16 1000 – 1250
19 1250 – 1600
25 1600 – 2200
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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.
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Figure 5 - Horizontal Position Gouging
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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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