Lesson 1Safe Pressure Levels and Regulator Adjustments for Common Mild Steel Plate CutsSummarises safe oxygen and fuel pressure levels for mild steel plates, proper regulator adjustments, and gauge readings. Stresses avoiding excessive pressure, backfires, and poor cuts by using stable, balanced settings in Zambian conditions.
Common pressures by plate thicknessAdjusting and balancing regulatorsReading and understanding gaugesAdjusting for preheat and piercingSpotting unsafe pressure indicatorsLesson 2Basic Metallurgy of Carbon and Mild Steel for Oxy-Fuel Cutting (Thickness, Oxidation, Heat-Affected Area)Introduces basic metallurgy of carbon and mild steel relevant to oxy-fuel cutting. Explains oxidation, heat-affected area behaviour, thickness impacts, and how steel composition and structure affect cut quality and bending in Zambian steelwork.
Carbon levels and steel typesRole of iron oxidation in cuttingHeat-affected area and hardnessThickness, mass, and heat distributionImpacts on bending and warpingIdentifying metallurgical flawsLesson 3Cutting Methods for Straight, Even Cuts (Torch Angle, Travel Speed, Preheat, Piercing)Explains torch handling for straight, even cuts, including proper torch angle, distance, and travel speed. Details preheat timing, run-on and run-off tabs, piercing methods, and keeping a steady, uniform cut line for Zambian boilermakers.
Torch angle and nozzle distancePreheat time and puddle formationPiercing steps and safetyControlling travel speed and cut widthUsing run-on and run-off tabsKeeping steady hand movementsLesson 4Edge Cleaning and Preparation After Cutting (Grinding, Slag Removal, Size Checks)Details post-cut edge cleaning with chipping, grinding, and filing. Explains removing slag and dross, deburring, and size checks using gauges and squares to ready edges for welding, fitting, or further work in Zambian shops.
Safely removing slag and drossGrinding and smoothing cut edgesDeburring holes and cornersChecking evenness and angleMeasuring length and straightnessPreparing edges for weldingLesson 5Marking, Layout, and Measurement for Cutting Rectangular Frame Parts (Scribing, Square, Templates)Covers accurate layout for rectangular frame parts using squares, scribes, and templates. Explains choosing reference points, transferring sizes from drawings, and marking methods that stay visible but limit surface damage in Zambian fabrication.
Reading drawings and sizesSelecting reference points and edgesUsing squares, tapes, and rulesScribing and punching linesUsing templates and guidesChecking diagonals and evennessLesson 6Pre-Use Checks and Leak Testing Steps (Visual Checks, Soap Test, Flashback Device Inspections)Outlines pre-use checks for cylinders, hoses, regulators, and torch. Explains soap solution leak testing, checking flashback devices, and verifying valves and connections to avoid gas leaks, flashbacks, and failures in Zambian settings.
Visual checks of hoses and jointsInspecting regulators and gaugesSoap solution leak test methodTesting flashback arrestorsVerifying valve operationRecording and tagging flawsLesson 7Oxy-Fuel System Parts and Upkeep (Cylinders, Regulators, Hoses, Torch, Tips, Flashback Arrestors)Describes oxy-fuel system parts and their roles, including cylinders, regulators, hoses, torch body, tips, and flashback arrestors. Covers basic upkeep, cleaning, and replacement times for safe, reliable use in Zambian boilermaking.
Cylinder valves and fittingsRegulators and pressure controlHose types, colour codes, and careTorch body, mixers, and valvesTip types, cleaning, and wearFlashback arrestors and check valvesLesson 8Common Practical Fixes and Quality Checks (Undercut, Taper, Dross)Focuses on spotting and fixing common cut flaws like undercut, taper, drag lines, and dross. Offers practical adjustments to speed, tip size, and pressures, plus simple quality checks for production in Zambian workshops.
Spotting undercut and washoutRecognising taper and angle errorsCauses of heavy dross and drag linesAdjusting speed, height, and angleFixing pressure and tip problemsSimple visual and gauge checksLesson 9Handling, Storage, and Identification of Cut Parts (Tagging, Stacking, Rust Prevention)Explains safe handling and storage of fresh cut parts, including identification, tagging, and position marks. Covers stacking methods, support use, and basic rust prevention to keep size accuracy and tracking in Zambian storage.
Tagging and part identificationMarking position and assembly sidesSafe lifting and manual handlingStacking, supports, and basesShort-term rust protectionWorkshop storage records and labelsLesson 10Gas Choices and Tip Sizing for Common Plate Thicknesses (Acetylene vs Propane, Suggested Tip Numbers)Covers choosing oxygen-fuel gas mixes and tip sizes for common mild steel thicknesses. Compares acetylene and propane performance, and lists typical tip numbers and flow rates for efficient, cost-effective cutting in Zambia.
Comparing acetylene and propaneGas choice by thickness and taskManufacturer tip charts and dataSelecting tip size and openingFlow rates and preheat adjustmentsEffects on cut speed and quality
