AIR CARBON GOUGING ELECTRODES
Alloy Type: SPECIALTY ELECTRODES , FILLERS, & GOUGING
COPPER COATED
AIR CARBON ARC GOUGING CARBONS
AIR CARBON ARC GOUGING DATA:
The air carbon arc process is flexible, efficient, and cost effective on practically any metal; carbon steel, stainless steel and other ferrous alloys; gray, malleable and ductile cast iron; aluminum; nickel; copper alloys and other nonferrous metals. Single-phase machines with low open-circuit voltage may not work for air carbon arc gouging (CAC-A). However, any three-phase welding power source of sufficient capacity may be used for air carbon arc gouging. The arc voltage used in air carbon arc gouging and cutting ranges from a low of 35 to a high of 56 volts; thus the open-circuit voltage should be at least 60 volts. The actual arc voltage is governed by arc length and the type of gouging. For most applications CAC-A is used with DCEP (reverse polarity). The electrode should extend at most 7 inches from the gouging torch with the air jet between the electrode and work piece. A minimum extension of 2” should be used to prevent damage to the torch parts. Normal compressed air pressures for CAC-A range between 80 psi and 100 psi at the torch; higher pressures may be used, but they don’t remove metal more efficiently. Use 60 psi (413.7 kPa) with the light-duty manual torch. The air hose supplying air to the torch body should have an inside diameter of at least 3/8” (6.4 mm).
SUGGESTED CURRENT RANGES FOR COMMONLY USED ELECTRODE TYPES AND SIZES
| ELECTRODE DIAMETER | DC ELECTRODE WITH DCEP | AC ELECTRODE WITH AC | AC ELECTRODE WITH DCEN | ||||
| In. | mm | Min Amps | Max Amps | Min Amps | Max Amps | Min Amps | Max Amps |
| 1/8 | 3.2 | 60 | 90 | – | – | – | – |
| 5/32 | 4.0 | 90 | 150 | – | – | – | – |
| 3/16 | 4.8 | 200 | 250 | 200 | 250 | 150 | 180 |
| ¼ | 6.4 | 300 | 400 | 300 | 400 | 200 | 250 |
| 5/16 | 7.9 | 350 | 450 | – | – | – | – |
| 3/8 | 9.5 | 450 | 600 | 350 | 450 | 300 | 400 |
| ½ | 12.7 | 800 | 1000 | – | – | – | – |
| 5/8 | 15.9 | 1000 | 1250 | – | – | – | – |
| ¾ | 19.1 | 1250 | 1600 | – | – | – | – |
| 1 | 25.4 | 1600 | 2200 | – | – | – | – |
RECOMMENDED MINIMUM AIR REQUIREMENTS
Recommended Compressor Rating
Air Pressure Air consumption Intermittent Use Continuous Use ASME Receiver Sz
| Type of Torch | psi | kPa | cfm | L/min | hp | kW | hp | kW | gal | litres |
| Light Duty (2) | 40 | 280 | 8 | 227 | .5 | 0.4 | 1.5 | 1.1 | 60 | 227 |
| General Duty (2) | 80 | 550 | 25 | 708 | 5.0 | 3.7 | 7.5 | 5.6 | 80 | 303 |
| Multipurpose (3) | 80 | 550 | 33 | 934 | 7.5 | 5.6 | 10 | 7.5 | 80 | 303 |
| Automatic (4) | 60 | 414 | 46 | 1303 | 15 | 11.2 | 80 | 303 |
1. Pressure while torch is in operation.
2. Accommodates flat electrodes.
3. Generally considered a foundry torch
4. Requires some kind of mechanical manipulation.
PERMISSIBLE NOISE EXPOSURE
Ear protection is recommended when noise from the air carbon arc process exceeds permissible levels as listed in OSHA 1910.95
| Duration Per Day | Sound Level DBA (in hours) Slow Response |
| 8 | 90 |
| 6 | 92 |
| 4 | 95 |
| 3 | 97 |
| 2 | 100 |
| 1 ½ | 102 |
| 1 | 105 |
| ¼ or less | 115 |
BLUE DEMON WELDING PRODUCTS