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Answers for buyers considering a powered or mechanised gouging system instead of working with a hand torch alone.
A mechanised system carries the gouging torch on a travelling carriage or similar arrangement, so the travel speed and the position of the torch are set by the equipment rather than by the operator's hand. A hand torch relies on the operator to hold the angle, stand-off and speed steadily.The process is still carbon arc gouging, with an arc melting the metal and compressed air blowing it out, so you still need a suitable power source, carbons and an air supply. The advantage is repeatability on long, regular grooves, such as back-gouging seams. For short or awkward work a hand torch is often more practical.
It tends to make sense where you gouge long, regular grooves often, such as seam back-gouging on thick plate. Independent trials by a welding research body found that mechanising back-gouging reduced gouging time substantially and also cut the clean-up time needed afterwards.More even grooves can also mean less metal removed and a smaller weld cross-section to fill, which in turn can reduce welding time, consumable use and distortion. For occasional, short or irregular jobs, or work in tight spaces, a hand torch is usually more flexible, so think about how much of your gouging is repeatable.
Generally yes for the groove itself. Gouging by hand takes considerable skill to keep a consistent groove shape and depth, and poor technique leads to uneven grooves and extra grinding afterwards. Mechanisation gives more precise control of the process and generally needs less operator skill for that part of the job.Operators still need training in setting up the machine, choosing current, carbon size and air, checking the groove and working safely. Treat the machine as helping with consistency, not as a replacement for understanding the process, and follow the manufacturer's instructions.
The same kind as hand gouging. The power source must have a constant-current output, and a DC supply with the electrode positive is the most suitable choice for steel. Arc voltage can be quite high, so the open-circuit voltage needs to be well above it; a typical guide figure is above 60 V.Mechanised work often runs at higher current and for longer periods than hand gouging, so check the power source can supply the current you need at the duty you will run. Look at the machine and power source data plates and manuals to confirm they are compatible.
Mechanised gouging commonly uses larger carbons and higher currents than hand work. Typical guide figures run from around 300 to 400 A on an 8 mm carbon to around 500 A on 9.5 mm, 850 A on 13 mm and 1250 A on 16 mm.These are only guides: the right setting depends on the groove you need, the material and the machine. Check that the torch, cable and power source are all rated for the current, and follow the carbon maker's recommendations. Our team can help you work out what suits your application.
The air is there to blow the molten metal out of the groove, so it needs to supply enough flow at the torch for that job. A compressed air line can supply pressure of up to roughly 100 psi, and more pressure or flow than is needed to clear the metal brings no extra benefit.Check the torch and machine manual for the pressure and flow they require, and use hoses, fittings and a regulator rated for it. Dry, clean air is best, so a filter or dryer in the line is sensible. Too little air leaves molten metal in the groove and raises the risk of carbon pick-up.