# HOW DOES THE METAL CUTTING PROCESS WITH METAL ELECTRODES WORK? Metal cutting with metal electrodes is an arc-based process that uses the intense heat generated by the electric arc to melt and sever metal. Below is a description of how this process works: ## Basic Principle The process relies on establishing an electric arc between a coated metal electrode and the base metal. The arc generates temperatures exceeding **6,000°C (10,800°F)**, which are sufficient to melt virtually any metal. ## Main Steps of the Process ### 1. Equipment Setup – A conventional **arc welding power source** is used (AC or DC) – The amperage is set **higher than that used for welding** with the same electrode diameter – DC with **electrode positive (DCEP)** polarity is recommended for better performance ### 2. Arc Striking – The electrode is brought into contact with the base metal to strike the arc – A **stable and continuous arc** is maintained throughout the cut ### 3. Cutting Action – The arc melts the base metal at the point of contact – The molten metal

It is possible to cut, pierce, gouge, and bevel metals by melting the metal using the intense heat of an electric arc established between a special electrode and the workpiece. A high-pressure jet of gas, produced by the combustion of the special coating, strikes the molten metal pool behind the arc and displaces it. Cutting speed varies depending on working conditions; these electrodes are used with conventional manual arc welding equipment, requiring no additional equipment or accessories.

WHAT ARE THE APPLICATIONS?

The electrode cutting process is used to cut, pierce, remove defective sections, remove old welds, back-gouge the root, and prepare bevels and grooves for welding on all types of ferrous and non-ferrous metals. The cutting area is small and, since the metal is melted and rapidly removed, the surrounding area does not reach high temperatures. This reduces the tendency toward distortion and cracking.

WHAT ELECTRODES CAN BE USED?

There are two types of electrodes for this process:

• For cutting and piercing, each manufacturer assigns its own trade name to this type of electrode.

• For beveling and gouging.

Electrodes are manufactured in diameters ranging from 2.5 mm to 6.3 mm.

ADVANTAGES.

With cutting and beveling electrodes, mild steel can be removed at a rate of up to 10 kg per hour, whereas a high-speed grinding disc can remove only a maximum of 2 kg per hour. Compared to the carbon arc cutting process, it has the advantage of not requiring additional compressed air equipment and its various accessories, while also eliminating the need for the special electrode holder required for carbon arc cutting.

When compared to oxyfuel cutting, it can be seen that this process is limited solely to cutting mild steels; by contrast, with special metal electrodes designed for this purpose, it is possible to cut, pierce, etc. any type of rolled, cast, or forged steel, as well as various grades of cast iron and stainless steel, along with copper, bronze, aluminum, and any non-ferrous metal or alloy.

 The process allows plates of various thicknesses to be cut by moving the electrode along the cut line in a sawing motion. To perform the cut, it is necessary to apply a motion that allows the molten metal and slag to flow out of the cutting zone.

To pierce small-diameter holes in thin plates, the arc is struck and the electrode is pressed downward until the hole is produced, then enlarged if necessary.

For beveling and gouging, any metal or metal alloy can be beveled and gouged. It also allows the removal of fatigued material or defective filler metal deposits. To produce grooves or channels, or to prepare bevels, the electrode is handled using an angled technique at 30°; with proper technique, well-defined grooves should be achieved.