Oxidation melting cutting is one of the most popular metal-cutting methods. It is relatively simple and inexpensive and has numerous advantages. It offers a precise and tailored cut. It is able to be done manually or machined by portable or large machines. It is able to be defined as “a process of sectioning metals by localized and continuous combustion due to the action of a jet of high purity O2, acting on a point previously heated by an oxy-fuel flame”.
Cutting materials is one of the most critical steps in the steel chain. The finished plates must be cut into pieces for their final destination, and the scraps must be cut into smaller pieces to facilitate their subsequent processing. The cuts are able to be divided by mechanics, by melting the metal, combining fusion and vaporization, and by chemical reaction.
The process typically involves six steps: material preparation, a laser beam focusing, applying the laser beam, melting, and evaporation, blowing away the molten material, and continuing the cutting process. On the other hand, oxidation melting cutting has numerous advantages, including high precision, high speed, minimal distortion, versatility, flexibility, and reduced tool wear.
What is Oxidation Melting Cutting?
Oxidation melting is a laser-cutting technique that involves melting and evaporating a material with a high-powered laser beam to create a cut. It is a method known as melt and blow cutting or fusion cutting. Another term for oxidation melting cutting is “fusion cutting.”
The laser beam warms the material to its melting point, causing it to melt and evaporate during oxidation melting cutting. The high-pressure oxygen gas is then utilized to blast the molten material away, resulting in a clean cut. This technique is well-known for providing smooth, burr-free edges when cutting metals like stainless steel and aluminum.
Oxidation melting cutting needs more laser power and oxygen gas pressure than other laser cutting methods, which raises operational expenses. Nonetheless, it is a very accurate and effective form of cutting often used for cutting heavier materials.
Oxidation melting cutting began in the mid-20th century when high-powered lasers were able to cut and weld metals. Laser cutting began with “vaporization cutting,” which entailed using a high-power laser to evaporate the material to cut it.
The laser beam was absorbed by metals, reflecting and scattering it, making vaporization cutting ineffective. Researchers developed the oxidation melting cutting technique by experimenting with high-pressure gas to remove molten material from the cut zone.
Researchers at the University of Stuttgart in Germany found that adding oxygen gas to the cutting process made it more efficient and able to cut thicker metals in the 1970s. Oxidation melting cutting since then has become a prominent process for cutting and shaping metal components in many businesses, evolving alongside laser technology and cutting methods.
Some properties and chemicals associated with oxidation melting cutting include high temperature, high-pressure oxygen gas, oxidation, precise cuts, and hazardous fumes.
How Does the Oxidation Melting Cutting Process Work?
Oxidation melting cutting is a laser cutting process that involves six steps. First, material preparation. Material preparation involves preparing the material to be cut and then positioning it on the bed of the laser cutting machine. Second, focusing the laser. The laser beam is focused by a lens or mirror system, which focuses the laser energy on a tiny spot on the material surface. The step of the process is known as “focusing the laser.”
Third, applying the laser beam. The laser beam is applied to the material, usually beginning at one edge and proceeding along a predetermined route to produce the desired cut form. Fourth, melting the material. The substance melts as it is heated by the laser beam, reaching its melting point quickly and beginning to melt and evaporate.
Fifth, blowing away the molten material. The molten material is blown away to make room for the laser beam and to make a clean cut using a high-pressure jet of oxygen gas. Lastly, continuing the cutting process. The laser beam keeps cutting until the whole sliced form is complete by following its predetermined path.
The melting process in oxidation melting cutting includes the laser beam heating the material to its melting point, causing the material to change from a solid to a liquid state. The laser beam is often concentrated to a tiny spot size, which aids in the concentration of laser energy and the production of a localized melting effect. The laser beam’s high temperature causes the material to evaporate, generating a plume of gas blasted away by the oxygen gas stream.
The cutting process in oxidation melting cutting comprises the laser beam traveling along a predetermined path, melting and evaporating the material. The high-pressure oxygen gas stream is utilized to clear the way for the laser beam by removing the molten material. A precise and accurate cut is achieved by carefully regulating the laser cutting parameters, including laser power, beam focus, cutting speed, and oxygen gas pressure.
What is the Use of Oxidation Melting Cutting?
Oxidation melting cutting, known as fusion cutting, is a laser cutting procedure used for cutting and treating a wide variety of metals, especially those that are difficult to cut using standard methods. Metals such as steel, stainless steel, aluminum, copper, and brass are all able to be cut with this method.
Cutting using oxidation melting is especially beneficial for applications that demand precise and accurate cuts with minimum distortion or heat-affected zones. It is a very efficient technique, with far quicker cutting rates than previous methods. This method is able to be used to cut a wide variety of thicknesses, from thin sheets to heavy plates.
The process is able to be used to cut metals such as steel, aluminum, copper, nickel, and titanium alloys, and precious metals. Meanwhile, some industries where oxidation melting cutting is commonly applied include aerospace, automotive, electronics, medical, jewelry making, architectural, signage, and industrial manufacturing.
What are the Benefits of Using Oxidation Melting Cutting?
Listed below are the benefits of using Oxidation Melting Cutting.
- High precision and accuracy: Oxidation melting cutting is a very accurate method that permits the fabrication of elaborate and complicated patterns with high accuracy.
- Minimal distortion and heat-affected zones: This procedure creates low distortion and heat-affected zones, which contributes to the high degree of dimensional accuracy and absence of warping and other distortions in the cut metal components.
- High cutting speeds: Oxidation melting cutting is a highly rapid cutting method that is able to greatly minimize the time necessary for cutting and processing metal items.
- Wide range of materials: It is able to be used to cut a wide variety of materials, including steel, aluminum, copper, nickel alloys, and precious metals.
- Flexibility: Oxidation melting cutting is a very adaptable method that is able to be used to cut metal pieces of varying thicknesses and dimensions.
- Automation: The process is readily amenable to automation, which reduces labor costs and boosts productivity.
- Reduced waste: Oxidation melting cutting generates low waste, which aids in minimizing material costs and environmental effects.
What is the Type of Gas used in Oxidation Melting Cutting?
Listed below are the type of gas used in Oxidation Melting Cutting.
- Natural Gas:
- MAPP (Methylacetylene-Propadiene):
- Acetylene:
- Propylene:
- Propane:
1. Natural Gas
Natural gas is mostly methane (CH4) with tiny quantities of other hydrocarbons, including ethane (C2H6), propane (C3H8), butane (C4H10), and non-hydrocarbon gases like carbon dioxide (CO2) and nitrogen (N2) (N2). It is made from millions-year-old plant and animal remnants buried in silt and rock. The earth’s crust’s heat and pressure turned organic materials into natural gas.
Drilling and pipelines carry natural gas from deep underground deposits to end-use markets. It heats buildings, generates energy, and powers cars. Natural gas burns cleaner than coal and oil, releasing fewer pollutants and greenhouse gases. It is non-renewable and has environmental implications during extraction and transportation.
Natural gas is utilized as a fuel for oxidation melting cutting (OMC) because of its high calorific value and clean-burning characteristics. A jet of high-pressure oxygen is directed onto the metal surface to be cut, and a fuel gas (such as natural gas) is used to heat the metal and commence the oxidation process in OMC. The heat created by the oxidation process melts the metal, and the oxygen jet removes the molten material, resulting in a precise and clean cut.
Natural gas provides various benefits over other forms of gas, such as propane and acetylene, when it comes to OMC. First, it generates a hotter flame than propane or acetylene, resulting in higher cutting speeds and shorter cycle durations. Second, natural gas is more accessible and affordable than other forms of fuel gas. Natural gas, as a cleaner-burning fuel, is able to minimize emissions and environmental effects.
On the other hand, natural gas has a few disadvantages as a fuel for OMC, such as limited availability, lower flame velocity, safety concerns, and less suitability for thicker metals.
2. MAPP (Methylacetylene-Propadiene)
MAPP (Methylacetylene-Propadiene) is a fuel gas used in welding, brazing, and cutting. It is made up of two hydrocarbons, methylacetylene, and propadiene, that are liquefied under high pressure for storage and transportation. MAPP gas is often used in welding and cutting operations as a replacement for acetylene since it generates a flame temperature comparable to acetylene but with certain distinguishing characteristics.
MAPP gas burns hotter than propane or natural gas, making it ideal for high-temperature applications. It has a quicker flame velocity than acetylene, which leads to faster cutting rates and more efficiency. Moreover, MAPP gas has a relatively consistent combustion profile, which helps lower the danger of flashback and other combustion-related risks.
MAPP gas differs significantly from other gases used for oxidation, melting, and cutting in a few crucial ways. Firstly, it cuts more rigid metals more effectively than propane or natural gas because it burns at a greater temperature. The second reason is that it creates a slightly altered flame form, which changes how the metal is sliced. Lastly, MAPP gas is able to be less economical for particular applications due to its higher cost than propane or natural gas.
MAPP has advantages as a fuel for OMC, such as high energy content, clean burning, safe to handle, versatility, and ease of igniting. On the other hand, there are disadvantages, including safety concerns, limited availability, cost, reduced cutting speed, and environmental concerns.
3. Acetylene
Acetylene is a gas with a distinct, colorless, and very combustible smell. Two carbon and two hydrogen atoms make up this molecule, C2H2. Acetylene makes polymers, synthetic rubber, solvents, welding, cutting, and brazing fuel gas.
A unique generator reacts calcium carbide with water to produce acetylene gas. The gas is kept in high-pressure cylinders, usually up to 250 psi, and supplied to the point of usage via a regulator.
Acetylene burns at high temperatures, making it perfect for cutting and welding. Acetylene combined with oxygen generates a flame that melts most metals at 3,500 degrees Celsius (6,332 degrees Fahrenheit). Acetylene gas is very unstable and is able to break down explosively if handled and stored improperly. Thus, safety precautions must be taken while utilizing it.
Acetylene burns hotter than propane or natural gas. It produces a hotter flame, which speeds up and improves cutting. Acetylene is suitable for accurate flame control in cutting applications because of its steady flame. Gases with less steady flames make cutting harder. Moreover, acetylene is safe for cutting, although it has hazards. Acetylene is combustible and unstable. Safer gases include propane and natural gas. It is able to be too pricey for specific purposes. It is cheaper in certain cutting situations because of its higher flame temperature and stability.
Acetylene has advantages as a fuel for OMC, such as high flame temperature, ease to control, versatility, efficiency, portability, and low toxicity. On the other hand, there are disadvantages, including safety concerns, limited availability, cost, health hazards, and environmental concerns.
4. Propylene
Propylene, having the molecular formula C3H6, is a colorless, flammable, and highly reactive gas. It belongs to the alkene hydrocarbon family and is often utilized as a fuel gas in cutting and welding operations. Propylene is utilized as a feedstock in the manufacture of a wide range of compounds, such as polymers, solvents, and synthetic fibers. The cracking of petroleum or the refining of natural gas creates it. Propylene is a versatile chemical with a wide variety of industrial and commercial uses, making it a valuable commodity worldwide.
Propylene differs from another oxidation melting, cutting fuel gases in various ways. Propylene is good for cutting and welding tasks that demand moderate heat since its flame temperature is lower than acetylene but greater than propane. Its flame is brighter and more uniform than acetylene’s, which is more aggressive and turbulent. Furthermore, propylene is less reactive and less explosive than acetylene. Its greater ignition point makes it more stable at high pressures than acetylene. It is more costly than propane but cheaper than acetylene, giving it a cost-effective solution for low-flame applications.
Propylene has advantages as a fuel for OMC, such as high heat output, safety, clean burning, cost-effectiveness, and versatility. On the other hand, disadvantages include lower heating value, sensitivity to impurities, limited availability, and reduced cutting speed.
5. Propane
Propane is a hydrocarbon gas extensively used as a heating and cooking fuel and in industrial operations like welding and cutting. It is a colorless and odorless gas, but a unique odor is added to it to aid in leak detection. Propane is stored and transported as a liquid in pressurized tanks, but when released into the open air, it vaporizes into a gas. It is a clean-burning fuel that emits fewer emissions than many other fossil fuels and is derived from natural gas processing and petroleum refining. Propane is employed as a refrigerant, a propellant in aerosol sprays, and fuel in vehicles like forklifts and buses.
Propane is one of the gases that are able to be used as fuel for Oxidation Melting Cutting. Other gases that are able to be used as fuel include acetylene, propylene, and natural gas. Some differences between propane and other fuel gases in this process include heat output, flame temperature, cost, availability, and safety.
Propane has advantages as a fuel for OMC, such as high energy density, clean burning, portability, versatility, and safety. On the other hand, disadvantages include lower heat output, limited availability, higher cost, poor performance, and potential safety risks.
What Materials are suitable for Oxidation Melting Cutting?
Some materials suitable for oxidation melting cutting include steel, cast iron, copper and brass, aluminum, and stainless steel. Steel is the material cut utilizing oxidation melting cutting the most often. It is often used in manufacturing, building, and other industrial applications. Moreover, cast iron is a brittle, rigid material that is able to be challenging to cut with conventional tools. Cast iron parts for machinery and automobiles are often cut using the oxidation melting cutting technique.
Copper and brass are often used for plumbing, electrical, and aesthetic purposes. Oxidation melting cutting makes quick work of cutting these materials. Furthermore, aluminum is a robust and lightweight material often used in aerospace, automotive, and other sectors. Aluminum is able to be cut by oxidation melting, cutting up to a specific thickness, although caution must be exercised to prevent warping or distortion. Additionally, stainless steel is a corrosion-resistant substance often used in manufacturing food, medical devices, and other items that must be hygienic and long-lasting. Stainless steel is able to be cut by oxidation melting, however, because of its high melting point, it is able to be trickier than cutting other materials.
Thermal materials are used for insulation, heat dissipation, and thermal management, not cutting. Certain materials are suited for oxidation melting cutting, known as flame cutting or oxyfuel cutting.
Oxidation melting cutting uses propane, acetylene, natural gas, and oxygen. Mixing and igniting these gases creates a high-temperature flame that melts and cuts metal.
Oxidation melting cutting equipment and tools employ thermally appropriate materials. Copper cutting tips, which carry heat and electricity, guide the flame onto the metal being cut. Copper tips are recommended for oxidation melting cutting because they are able to tolerate high temperatures and maintain a consistent flame.
Many materials used for Laser Cutting fall within the 0.5 mm to 250 mm thickness range. Some examples are metals, plastics, glass, wood, and stone. The particular thickness needed for a specific application relies on the material’s characteristics, the usage for which it is designed, and other elements.
What is the Best Oxidation Melting Cutting Machine?
There are several oxidation melting cutting machines on the market, and the “best” machine for a particular application is going to be determined by various criteria, including the kind and thickness of the material being cut, the needed cutting speed and precision, and the available budget. Some popular brands of oxidation melting cutting machines are ESAB, Hypertherm, and Lincoln Electric.
ESAB provides a comprehensive line of oxidation melting cutting machines, including oxy-fuel and plasma cutting systems. These devices are well-known for their fast cutting rates and precision.
The cost and ratings of ESAB machines vary based on the model’s characteristics and specifications. ESAB Purox® CW300 Oxy-Fuel Cutting Machine is a manual oxy-fuel cutting machine capable of cutting materials up to 8 inches thick. It is tiny and simple to set up and use. The estimated price range for this device is between $1,500 and $2,000. Moreover, ESAB Sabre® DX2000 Plasma Cutting Machine is a CNC plasma cutting machine that cuts materials up to 1.5 inches thick. It offers a high-speed cutting function and powerful software capabilities. It is estimated to cost between $30,000 and $40,000.
On the other hand, ESAB machines are known for their quality, sturdiness, and precise cutting capabilities and are usually regarded favorably by consumers. The particular ratings for each machine depend on variables such as the machine’s model, features, and user feedback.
Hypertherm is a company specializing in handheld and automated plasma-cutting machines. Precision cutting capabilities and excellent software features distinguish their devices. Hypertherm is a major plasma-cutting machine producer with versions for all budgets. A simple Hypertherm plasma-cutting machine costs a few thousand dollars, whereas an industrial-grade unit costs tens of thousands. For example, Powermax30 costs around $1,500, while Powermax105 costs $15,000. Hypertherm plasma cutting machines are highly rated for dependability, speed, and performance. Advanced software on Hypertherm machines improves cutting accuracy and reduces waste.
Lincoln Electric is among the Best Laser Cutting Machine and provides oxy-fuel and plasma cutting equipment and CNC cutting systems. These devices are well-known for their dependability and longevity. The cost of Lincoln Electric cutting machines varies according to the model and features. Entry-level versions start at $1,000, while more complex ones are able to cost $10,000 or more.
Lincoln Electric has a solid reputation for manufacturing high-quality, resilient, effective, and efficient equipment. They are well-known for their meticulous attention to detail and dedication to client satisfaction. Customers and industry professionals have given excellent feedback on several of their cutting equipment.
Does Oxidation Melting Cutting is faster than other Types of Cutting?
No, oxidation melting cutting is not faster than other types of cutting. It is often significantly slower than other cutting techniques, such as plasma or laser cutting, when cutting dense materials.
The cutting speed of oxidation melting relies on a number of parameters, including the thickness and kind of material being cut, the size of the cutting torch or nozzle, the flow rate of the oxygen and fuel gases, and the skill level of the operator. Oxidation melting is often slower than plasma or other Types of Laser Cutting since it includes a physical process of melting the metal with a flame instead of slicing through it with a focussed beam of energy.
Does Oxidation Melting Cutting have high Melting Power?
Yes, oxidation melting cutting has high melting power. It melts and cuts metal using a high-temperature flame. A fuel gas (such as acetylene or propane) and an oxygen gas are mixed in a torch and ignited to produce a flame with a temperature of up to 3,500 degrees Celsius (6,332 degrees Fahrenheit).
The high-temperature flame produced in oxidation melting cutting has a high melting power, allowing it to melt and cut through a variety of metals such as steel, cast iron, and aluminum. The flame’s melting power is able to be changed by adjusting the flow rate of the oxygen and fuel gases, which influences the size and intensity of the flame.
Oxidation melting cutting is slower than plasma or laser cutting, significantly when cutting dense materials. The oxidation melting cutting speed is determined by a number of criteria, including the thickness and kind of material being cut, the size of the cutting torch or nozzle, the flow rate of the oxygen and fuel gases, and the operator’s skill level.
Does Oxidation Melting Cutting have a fast Melting Speed?
No, oxidation melting cutting does not have melting speed. Cutting using an oxidation melting process is a dependable and inexpensive method for working with a wide variety of metal thicknesses and kinds, although it is not often thought of as a fast melting method. It’s because the procedure requires physically melting the metal with a flame, which is often slower than cutting through metal with a focussed beam of energy, as in laser or plasma cutting.
The speed at which metal melts varies on a number of variables, including the thickness and kind of metal being cut, the size of the cutting torch or nozzle, the flow rate of the oxygen and fuel gases, and the operator’s expertise.
Nevertheless, oxidation melting cutting is still a dependable and efficient technique that is especially well-suited for thicker metals and situations where precise cutting is not necessary, even if it is not the quickest melting process currently available.
Does Oxidation Melting Cutting have a quality Melting Cut?
Yes, oxidation melting cutting has a quality melting cut. Generally, oxidation melting cutting is able to create high-quality cuts on various metal kinds and thicknesses. Nevertheless, the procedure is not as exact as other cutting technologies, such as laser or waterjet, which are able to create highly fine slices with little heat-affected zones.
The quality of the melting cut generated by oxidation melting cutting varies based on numerous variables, including the metal being cut, material thickness, and operator skill level.
Many variables impact the quality of the melting cut generated by oxidation melting cutting. The size of the cutting torch or nozzle, for example, is able to influence the cut’s quality, and so is the flow rate of the oxygen and fuel gases. Additionally, the operator’s expertise and skill level have an impact on the quality of the cut made.
Overall, oxidation melting cutting does not make the most precise cuts, but it is still a reliable and cost-effective way to cut a wide range of metal types and thicknesses with high-quality results.
What is the difference between Oxidation Melting Cutting and Vaporizing Cutting?
Oxidation melting and vaporizing cutting are both ways of cutting with heat used in industry. Both methods use heat to cut through metal, but there are some important differences between the two.
Oxidation Melting Cutting
- Known as oxyfuel cutting
- Uses a high-temperature flame to melt and cut through metal
- Fuel gases, such as acetylene or propane, are combined with oxygen gas to create the flame
- The heat from the flame melts the metal, which is then blown away by the force of the oxygen gas
- Generally used for cutting thicker metal sections
- The cutting speed is generally slower than vaporizing cutting
- The quality of the cut varies depending on the operator’s skill level but is generally good
Vaporizing Cutting
- Known as laser cutting
- Uses a focused beam of energy to vaporize the metal and create a cut
- A laser typically generates the beam, but other sources of energy is able to be used as well
- The process creates a narrow kerf and minimal heat-affected zone, resulting in a high-quality cut with excellent precision
- Generally used for cutting thinner metal sections, but it is able to be used for thicker materials
- The cutting speed is generally faster than the oxidation melting cutting
- Requires specialized equipment, including a laser or other energy source, and is able to be more expensive than oxidation melting cutting
Overall, oxidation melting and vaporizing cutting have pros and cons and are best for different types of cutting. Oxidation melting cutting is usually used to cut through thicker sections of metal. Vaporizing cutting, on the other hand, is better for cutting through thinner sections and requires special tools. Furthermore, vaporizing cutting is usually more precise and makes cuts of higher quality, but it is able to cost more than oxidation melting cutting.