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Refresher course : Module-06
Part-1 : Introduction
Part-2 : Welding & related processes
Part-3 : Brazing and soldering
Part-4 : Cutting & edge preparation
Part-5 : Plasma Cutting
Part-6 : Thermal Cutting Standards
Part-7 : Safety
IIW-ANB refresher course for Transition candidates 2
Part-1
Nozzle
Correct mixture
Neutral Greenish, rounded
inner cone
Excess of O2
Oxidising Blueish, sharp
inner cone
Excess of FG
Reducing Long white
luminous feather
Acetylene ( C2H2 )
Propane ( C3H8 )
LPG ( Mixture of propane and butane )
Methane (CH4 ) - Natural gas
Hydrogen ( H2 )
Propylene ( C3H6 )
Butane ( C4H10 )
OXY OXY-LPG
ACETYLENE
WELDING
TORCH
OXYGEN AND
ACETYLENE FLASHBACK
HOSES ARRESTORS
Assembly to be made by
self-locating or non-interfering
fixturing
SS & Heat
Ni Alloys >875
Resisting Alloys
Al & Al bronze
Brass
Copper
Steel/SS
Cast iron
Tin & Tin bronze
Zinc
IIW-ANB refresher course for Transition candidates 38
Fluxes
Inorganic fluxes Organic fluxes
Zinc chloride Stearic acid
Ammonium chloride Oleic acid
Tin chloride Glutamic acid
HCl Hydrazine hydrobromide
Phosphoric acid Acid based or acid
Metal chloride forming organics
Solder Workpiece
Sn-Sb-Pb Copper, brass
Sn-Zn Aluminium
Sn-Ag, Sn-Cu SS, copper,
Cd-Ag Aluminium
Zn-Al Aluminium
Brazing Soldering
Mixed gas
Cutting oxygen
Cutting Nozzle
Pre-heat flame View from the bottom
CUTTING STREAM
DRAG LINES
DEFECTS CAUSES
Fluted cut
Low speed
-gouging at the bottom
Carbon 0.3
Manganese 10
Silicon 2
Chromium 5
Nickel 3
IIW-ANB refresher course for Transition candidates 52
SPEED / CONSUMPTION (%)
Effects of oxygen purity
175
150
O2 CONSUMPTION
125
100
75
50
CUTTING SPEED
25
100 99.5 99 98.5 98
O2 PURITY %
1.0
m/min
0.5
0.25 STANDARD
0 10 20 30 40 50 60 70
PLATE T H I C K N E S S mm > >
IIW-ANB refresher course for Transition candidates 54
Plate Edge Preparation
Flame Planing Machine
Torch
CONTROLS Carriages
TBA
WORKPIECE
Scrap
CUSTOMERS
ORDER DESIGN
BOM DXF
FILES
FINISHED
GOODS PRODN PART TOOL PATH CNC
PLANNING LIBRARY NESTING GENERATION CUTTING
RAW PROGRAMMING
GRAPHIC
MATERIALS MIS MIS
STATION
EDITOR
COUNTER
CLOCKWISE
TRAVEL KERF OFFST =
KERF WIDTH
ON RH SIDE
CLOCKWISE OF TRAVEL
TRAVEL
START
SCRAP
DESIRED JOB
DIMENSION
JOB
KERF
LEFT RIGHT
INSIDE CCW CW
PROFILE
OUTSIDE CW CCW
3-5 20-25
mm mm 3 4
1 2
Preheat Retract Release O2 Normal
& Move
IIW-ANB refresher course for Transition candidates 62
Part-5
PLASMA
GAS
PLASMA
CUTTING
TORCH
SECONDARY
GAS
RECTIFIER HIGH
POWER FREQUENCY
SOURCE SOURCE
IIW-ANB refresher course for Transition candidates 66
Air plasma
Steam Layer
T-1>T-2>T-3>T-4
T-1
T-2
T3 WORKPIECE
T-4
TAPER CUT
SURFACE
IIW-ANB refresher course for Transition candidates 70
Water Injection Plasma
Underwater cutting
Pre-heat flame
Oxygen stream
Thermal Cutting
Standards
1 2 3 4
Main Perpendicularity/
Mean height Tolerance
number of angularity
of profile RZ5 class
standard tolerance, u
Angularity of Roughness of
cut surface Dimensional
ISO 9013 cut surface to
along cutting accuracy
plate surface direction
IIW-ANB refresher course for Transition candidates 88
Part-7
Safety
Protection Protection
Recommendation
of from
Use correct goggles
IR Radiation,
Eyes -shade # 3-6 for cutting
Spatter
-shade # 4-8 for welding
IR Radiation,
Skin Spatter, Wear leather gloves & apron
Hot metal, Burn
Apparel Spatter, Fire Wear apron
Flame
Symptoms
A bang Pressure MIXED
Wave GAS
Gouging
1) S. Ghoshal
1) Ranajoy Banerjee