Use CC DCEP.
Be sure the electrode is centered in the V contact point in the electode holder.
Use a slight push angle regardless of position; flat, overhead, or vertical.
Keep the air holes directly behind the electrode's direction of travel.
Keep the tip of the electrode extension within about 6" of the electrode holder to get an adequate amount of air at the electrode tip.
Don't push so fast the electrode rubs hard at the leading edge of the gouge. You can't go too slow when you are first learning, but you can go too fast.
More light cuts are easier to manage than fewer heavier cuts.
Don't foreget to turn on the air!
Carbon Arc Cutting, commonly called: Air Arc, Carbon Arc, Gouging, is truly an art. Doing it properly takes practice. Using the right electrodes for your application (biggest is not always BEST), the right air pressure (more is not usually BETTER), the correct amperage for the electrode and work requirements (highest possible is not recommended) and then getting the air ports on the correct side and angle to do the cleanest possible job.
You would truly be amazed by what an experienced hand can accomplish with Air Arc.Light skimming to get penetration, heavy material removal to repair or replace parts, cutting of excess material, and much more.
There are several constructive suggestions within this thread. Ear protection (plugs at the least, more if possible), respiratory (dust mask at the least, off the back fresh air positive air flow supply if possible), Protective clothing (Carharts or leathers highly recommended), Good Welding Gloves, proper hood/lens shade protection, Boots with good stitching that won't burn up and no holding area for sparks on the top especially where the tongue comes down to the main part of the boot.
Bottom line, time, practice, safety. Keep at it. It is worth knowing how to do and do well.
Have a Great Day, Brent
RC,
Not to be contradictory, I would be careful about calling it 'safer'. Depends upon several factors. First, to me, being what areas you refer to when calling it 'safer'. The fumes that come off of plasma have been rated pretty high on the hazardous scale. Not good stuff to breath at all. The plasma stream can take a finger off that won't happen with arc air as your finger won't conduct electricity. (My plasma will run a couple of seconds without being close to ground but will shut down quickly when no ground is attached. Will put a good gouge in the steel before shutting off.)
In some comparisons I ran between a large plasma and air arc on heavy equipment components I found the air arc to be faster, cleaner and just plain more managable in the tight areas I needed to use it than the plasma.
Now, everyone's application is different. Some may find their use more profitable and clean with the plasma. These are just my personal conclusions for my specific applications.
Another safety item: When using air arc or plasma indoors, a good exhaust/ventilation system is very necessary. The best one I worked with had louvers on one end of the weld shop and exhaust fans with louvers at the other end. When I turned on the fans and all louvers opened up the air moved through at a rate that would keep your air pure from several users at the same time. The lower level air did not move fast enough to be a problem for the gas shielding while the upper air moved at a pretty high rate and kept all contaminants sucked out very nicely. (Even works if you are running air arc with a gas or diesel power source.)
Have a Great Day, Brent
By rcwelding
Date 11-04-2010 01:33
Edited 11-04-2010 01:39
I have not run a gouge enough to have a strong opinion of it... All I remember is that it was LOUD and threw big chunks of slag like a son of a gun... Most of my work is in the field so I don't worry about fumes too much... My plasma may not take as big of a swath as a gouge but it seems twice as fast between passes as a gouge from what I remember.... I don't remember how much air a gouge takes but I think the plasma will run off of a smaller compressor.. Mine is a 1 1/4 machine and I can push it with a gas 5.5hp 10.3 cfm compressor just fine...
I need to run a gouge again to have a strong opinion as to which one I like better. As for now and for my application I am very happy with my plasma... It is also allot easier on my machine than a gouge... I was just trying to give the original poster another possible option to look into....
Here is another question for you guys... I haven't had the need to do it yet since I have owned my plasma but what will remove hardfacing better... Plasma or a gouge... I have had the joy in the past of blowing it off with a torch and a grinder... Both were terrible at removing it... I hope I never have to do it again but what do you guys think is the best tool for that nasty job..???
RC