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Fuel and Cutting

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Fuel and Cutting Gases

Industrial gases are essential to a wide range of fuel and cutting applications. Choosing the right gases is crucial to maximizing efficiency, accuracy and safety. With Meritus Gas, you can connect with gas and welding supplies distributors that support your operations.

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Understanding Different Types of Fuel Gases

Cutting and fuel applications encompass many types of gases that offer unique benefits based on their use.

Oxygen is the industry standard for cutting mild steel because it offers a clean and fast cut. When oxygen plasma gas interacts with carbon steel, it produces a fine spray that’s easy to eject from the kerf.

In oxy-fuel cutting applications, oxygen is mixed with a fuel gas like propylene or acetylene to create different types of flames for cutting. Some gases offer a hotter flame than others, which is ideal for specific metals.

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Welders will often use nitrogen for plasma-cutting aluminum and stainless steel. This gas is also used for laser-cutting applications. Increasing nitrogen pressure enhances the cutting speeds, allowing for a clean cut for mild steel and thick stainless steel sheets. Nitrogen for cutting applications requires specific purities for a clean cut. Sourcing this gas from trusted suppliers is essential for successful laser-cutting processes.

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Acetylene (C2H2) is a fuel gas often used in oxy-fuel applications. This fuel gas is the hottest and most efficient one available and can offer impressive productivity for cutting and welding applications. Acetylene is the only fuel gas that can be used to cut steel, and it’s lighter than air, making it ideal for underground working conditions.

Acetylene’s low hydrogen content makes it ideal for oxy-fuel cutting and welding. As a cutting fuel, the flame’s inner cone contains around 507 British Thermal Units (BTUs), while the outer cone provides around 963 BTUs. These characteristics allow for swift piercing with a small heat-affected zone. 

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Propane (C3H8) is an excellent fuel alternative to natural gas because it burns cleanly and offers a high octane rating for combustion engines. It’s an inherent by-product of natural gas and powers various appliances, from water heaters and refrigerators to industrial equipment. Propane forklifts are becoming increasingly popular, offering long run times and clean burning for indoor use.

In addition to powering many critical devices, propane can also serve oxy-fuel applications. In particular, oxy-propane is employed for preheating before using oxy-acetylene. While propane can generate as high a temperature as acetylene, it’s a cost-effective option that offers high enough temperatures for preheating.

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Hydrogen (H) is used to power fuel cells that generate carbon-free electrical power. The concept of hydrogen power is not new, but many fuel cell technologies are still in development. Most commonly, these fuel cells help produce biofuels. As a cleaner alternative to other known fuel sources, hydrogen fuel cells may become more common and accessible as technology advances.

In addition to hydrogen’s role in fuel cell technology, it’s also used in generator cooling and chemical processing.

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Gas Selection Guide for Industrial Applications

Selecting the ideal gas for a particular fuel-cutting method depends on several factors:

  • Cost: It is essential to consider the cost dynamics of using different cutting gases. For instance, while acetylene offers fast cutting speeds, it is generally more expensive than propane and propylene. Propane and propylene could be more cost-effective alternatives for certain applications.
  • Material type: Different materials require different gases and techniques for optimal cutting. Oxygen is best for mild steel, while nitrogen is effective for cutting aluminum and stainless steel in laser and plasma cutting.
  • Efficiency: Evaluating the flame temperature, heat distribution and calorific value is critical when considering different types of fuel and cutting gases. For example, acetylene produces a higher flame temperature, enabling faster piercing and reduced distortion in the workpiece. In contrast, propane offers a higher calorific value of approximately 2,150 BTU, making it an excellent alternative for preheating applications.
  • Gas purity: The purity of the gas affects the cutting quality. A 1% drop in the purity of oxygen, for instance, increases gas consumption by 25% and lowers the cutting efficiency by 25% in oxy-fuel cutting. 
  • Availability: Some gases, like acetylene, are more widely available than others.
  • Application-specific demands: It is critical to assess your project’s exact needs and preferences. Acetylene produces a significant amount of slag, which requires more clean up after the cut. This gas is also more susceptible to flashbacks. A flashback is where the flame burning in the torch ignites the gases in the hose, regulators or even the cylinders. As a result, you should use flashback arrestors whenever cutting using acetylene.

Cutting Equipment 

The right equipment is just as important as choosing the ideal gas for optimal cutting. 

Oxy-Fuel Cutting

This method uses a combination of oxygen and a fuel gas such as acetylene or propane. A typical oxy-fuel cutting system comprises:

  • A torch to direct the flame and oxygen onto the workpiece.
  • Regulators for pressure control of the gases.
  • Cylinders that store the gases. 
  • Cutting tips of different sizes based on material thickness and type.

To keep this system performing optimally, clean the tips and inspect the regulators regularly for leaks. Also, ensure the hoses are in good condition.

Plasma Cutting

Plasma cutting uses ionized gas (plasma) and electricity to create a high-temperature arc for cutting conductive materials, including aluminum, brass and copper. The plasma cutting system consists of a plasma torch which directs the arc to the workpiece, power supply and an air or nitrogen supply. Plasma cutters require periodic cleaning of the torch, nozzle and electrodes to maintain cutting performance.

Laser Cutting

Laser cutting uses high-energy laser beams to melt and vaporize metal for precise cuts. The system consists of a laser head to focus the beam, a laser source and a gas (usually oxygen or nitrogen) that helps remove the molten material from the cut area. Regular maintenance of the laser source and focusing lens is critical to maintain the beam’s precision.

Cutting Gas Applications and Equipment Compatibility

Cutting gases are invaluable in numerous industrial processes:

  • Metal fabrication: Gases such as acetylene and propane are commonly used in metal fabrication across a wide range of industries.
  • Ship building and construction: Oxy-fuel and plasma cutting can cut through thick metals ideal for heavy-duty industries such as ship-building and construction.
  • Automotive and aerospace industries: Precision cutting methods such as laser and plasma cutting are critical in the motor vehicle and aerospace industries. 

Our Gas Partners

Meritus Gas Partners is a group of independently operated gas suppliers housed under a single corporate umbrella. This structure allows Meritus Gas to provide the enterprise resources our suppliers need while offering attentive customer service and a personal touch that leads to long-term relationships.

Our partners are located throughout the United States to make their gases accessible to you. Learn more about each of our partners:

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Connect With a Supplier Near You

Find a partner near you to order the gases you need for fuel and cutting applications. You can also reach out to the Meritus Gas team to learn more about our business model.

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