A welder is assigned to remove an existing fillet weld on a thick steel plate using carbon arc gouging. After starting the arc, they observe that the molten metal is not being efficiently removed from the gouge path, and the carbon electrode is overheating quickly. Which of the following is the most probable cause?

Question: A welder is assigned to remove an existing fillet weld on a thick steel plate using carbon arc gouging. After starting the arc, they observe that the molten metal is not being efficiently removed from the gouge path, and the carbon electrode is overheating quickly. Which of the following is the most probable cause?

Answer options:

• The air pressure is too high, causing excessive cooling of the electrode.
• The electrode is too small for the amperage being used. ✅ The gouging angle is too shallow, preventing effective molten metal expulsion.
• The DC electrode negative (DCEN) polarity is being used instead of DC electrode positive (DCEP).

Correct answer: The gouging angle is too shallow, preventing effective molten metal expulsion.

Explanation: A shallow gouging angle (less than 30-45 degrees to the work surface) will not allow the air jet to effectively blow away the molten metal, leading to poor metal removal and potential carbon inclusion. While electrode size can affect overheating, the primary issue described with molten metal removal points to the angle. DCEN is generally preferred for carbon arc gouging, making DCEP incorrect in this context.