Arc Carbon Gouging

admin

So, I'm a hobbyist with a 155 AMP inverter that does Stick and TIG.I need to cut 2 strips of 1.5 x 6 inch strips out of a half inch thick piece of mild steel plate.My Dewalt chop saw just isn't cutting it. I've tried a 1/8th inch and a 7/64 inch abrasive blade, and they both take material off, but just barely.Since this is expected to be a one time need I just can't justify the cost of a plasma cutter or some exotic expensive blade for the chop saw, but I recently discovered something called "Arc Carbon Gouging".Since I can get the Carbon Electrodes cheap, my question for those with practical knowledge and experience with this method of cutting is, can I simply use my stick clamp along with a handheld blower for my air compressor to complete this small job, or is there something special about the ArcAir clamps that isn't apparent other than the fact that they have compressed air orifices built into them?Note, I'm okay with a low duty cycle slowing down the process, it will still be lightyears faster than what I'm doing now which is just eating away a little bit at time everytime I see the plate sitting in my chop saw...Thanks,Bill
Reply:Hmm... maybe try some of those "cutting" rods that Hobart sells? I've never tried them but it's worth a shot.I've cut 3/8 x 1.5" with just a cut off wheel on a grinder before... I got two pieces cut before I noticed anything gone from the cutting disc... IMO that's the method I'd use for such a small number of pieces.
Reply:Forget Arc Air."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:hmmm. gouging and cutting are different things. Im sure there would be a better way. I d put a cut off in my grinder like someone already said
Reply:Get a coarser blade from a welding store, You should be able to cut it with what you have.  Carbon arc will not do it for you. Even with a perfect arcair set up it is great for gouging off old welds etc, but won't cut clean.  You might have to have someone else cut it for you, or go to a metal supply and get the sizes you need already cut.
Reply:You can "cut" with 6010/11 rods if you crank the amps up as far as they will go and use a sawing action. It's not fast, it's not clean, but it will sever material if that is all you have.As mentioned you should be able to cut that material with your chop saw. The problem with cutting thick flat material with an abrasive blade is that the blade tends to load up when it can't clear the sparks. The pores of the blade become clogged with glazed material and it simply won't wear any more. If you try and cut some smaller material on edge, angle held in the vise like an L or a vertical piece of flat, you can often wear off the edge and loose the glazed material. I've also used a chunk of stone/ brick to break the glazing on gas powered demo saw abrasive blades. Cutting the hard surface briefly usually will wear the edge and expose fresh cutting surface.Best way to cut thick material is with it edge up vs in the flat position. Down side is that usually means you can't get all the way thru the material and may have to flip the piece to cut it. Other wise you just have to take it in small tries and keep "cleaning" the blade frequently.There are other ways to do this. A ferrous steel blade in a circular saw for example. Most are not rated at 1/2", but I've seen guys cut material that thick with them. I'd opt for using a straight edge and making a few shallow passes if I had no choice but to go that route. Note a carbide blade in an abrasive saw will not work. The ferrous blades for circular saws are designed to run at the lower RPM's hand held saws use. An abrasive saw runs too fast for large diameter carbide blades to work.You might want to just take a minute and add your location to your User CP at the top left, so we all know where you are located. Some one with a torch or horizontal bandsaw, could cut this in minutes for you..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Your abrasive saw should cut the stock. It will be slow, but it is very doable. Here is 1/2 in stock that is 3x4 that was cut out of old angle iron. some of the stock was cut with a torch, some a band saw, and some with an abrasive saw.The old steel yard I use to buy metal from had a large abrasive saw wheel on a shop built saw and it would cut all stock from beams on down.
Reply:For about $300 you can get the Milwaukee 8" metal cutting skill saw that you will find a lot of uses for in the future. They are so so handy and will cut that 1/2 plate like most skill saws cut plywood. I agree with all the others that gouging or air arc would not leave a surface that you could use.
Reply:Originally Posted by TSCGG13Hmm... maybe try some of those "cutting" rods that Hobart sells? I've never tried them but it's worth a shot.I've cut 3/8 x 1.5" with just a cut off wheel on a grinder before... I got two pieces cut before I noticed anything gone from the cutting disc... IMO that's the method I'd use for such a small number of pieces.
Reply:Bill I know you don't want to pick more tools up but check out the HF bandsaw.  Bandsaw is the way to go for material like this - always try and cut it in a thin cross section if possible.Miller Diversion 180Hobart Handler 140 (Soon to be replaced with Miller 211?)Miller Spectrum 625 Extreme
Reply:Thanks Jon, unfortunately I'm on short term disability which may become long term... and cut my income by 1/3 so spending money on new tools in the near (and possibly distant) future just isn't gonna happen
Reply:Carbon arc takes a lot of amps! I don't think your little welder will do it. I have cut 1/4 with a miller dialarc but it took 180 amps to do it. Not to mention the electrode holder will cost about $500. Better off just buying a cutting torch
Reply:Bill, just call a local metal supplier and see if they can knip off a few pieces from a drop."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder