ULTRA -THERMAL GOUGING AND CUTTING.
Ultra-thermal flame cutting offers benefits compared to other cutting processes, because of its high operating temperature, the little time that is required to put it in operation, its portability and its safety.
For the maintenance of industrial materials and machines, ultra-thermal cutting is complementary to traditional oxyacetylene and air carbon arc cutting. Ultra-thermal cutting is a burning process fuelled by oxygen. The system can be used to remove the teeth of loading shovels of excavating machines; it removes bolts and rivets, cuts construction steel on shipyards; drills, cuts and gouges on ship's decks. The ultra-thermal method has benefits over other methods because of its high operation temperature, its simple application, the little time that is required to put it in operation, its portability and its safety.
Ultra-thermal equipment comprises a cutter, ultra-thermal cutting electrodes, a copper ignition plate, an oxygen source with reducing valve, a 12 volt battery, an oxygen hose and cables. The cutter has a pistol grip with a copper manifold and a collet plus nut holding the electrode. A valve plus handle regulates the flow of oxygen through the cutter. The ignition plate is connected to the battery in order to ignite the electrode.
THE ELECTRODE IS THE KEY. The ultra-thermal electrode was originally developed in 1978 for use under water at offshore oil platforms. They replaced the less effective electrodes made of steel pipe. When the oil industry slowed down in the eighties, manufacturers redeveloped the electrode for use above water. A hollow, copper-coated steel pipe filled with wires made of steel alloy forms the electrode, the heart of the process. Circular notches in the pipe will keep the steel wires in their place. The user can bend the pipe in order to reach difficult places. Inside, the wires are a little shorter at one side of the pipe in order to prevent sparks backfiring. The user inserts the hollow parts of the electrode in the cutter. Oxygen will flow through the pipe and around the wires. Contrary to air carbon arch gouges, you do not need a welding device or compressor. Moreover, there is no danger of high currents, noise or smoke. The process does not build up carbon and does not require prior cleaning or sanding the workpiece. In order to cut with the electrode, the user will pull it over the workpiece. The working angle at the surface can fluctuate between 45 and 90 degrees; always keep the tip in the groove in order to prevent backfire. Melted material must be blown out of the groove in a forward direction; if is flows backwards, you must work at a lower pace. The oxygen pressure is 2.1 to 2.8 Bar for soft steel and iron up to 1.5cm thick; 2.8 to 3.5 Bar for non-ferrous metals up to 2.5cm and iron of 1.5 to 2.5cm.; 3.5 to 4.2 Bar for all metals up to 5cm and 4.2 to 5 Bar for all heavier work.
BENEFITS
UNIQUE POSSIBILITIES.
The unique method of burning with ultra-thermal electrodes will make literally all encountered materials fluid, while the material itself is used as fuel. They cut or melt through any known material, such as cast iron, steel, stainless steel, concrete, granite, nickel, titanium and aluminium. The electrode can drill through and cut thicker workpieces, gouge away cracks and heavy welding joints and remove deposits. The maximum cutting thickness in steel is virtually unlimited. Because our systems are able to cut so quickly, there is a minimum build-up of heat, as a result of which tempered materials remain virtually unchanged. Our ultra-thermal electrodes burn in moist surroundings, even in mud or water. This unique performance adds a very important benefit over other equipment, especially within industries with difficult working environments such as mining or heavy industry.
TIME AND COSTS SAVING PERFORMANCE.
If time saving is the criterion, then this system will be the professional's first choice for applications such as gouging, drilling or cutting. Maintenance and repair companies are able to perform difficult tasks much quicker, that would be very time-consuming with conventional methods. The time that heavy excavation machines are out of operation is dramatically reduced when removing attachment pins from the caterpillars or repairing them. Or when removing solid deposits. This system saves costs and working hours. Because our ultra-thermal systems operate at temperatures over 5000°C, it is not necessary to pre-heat the surface. As no permanent electric energy is required, repairs can be performed without burr formation on roller bearings and bushes. Moreover, you do not have to sand or clean surfaces when gouging, as our system does not deposit carbon.
SAFETY AND USER COMFORT.
This system is safer than other systems, as no high currents or potentially dangerous acetylene or any other fuel are required. The comfort and safety of the user are also improved, as this system produces less noise, smoke or toxic gases than other systems. The user friendly characteristics were designed with focus on simplicity in use. The 12 Volt DC ignition system, single 0² source with reducing valve and fully autonomous portable sets make sure that this system is easy to use.….even for a beginner.
