1
Match tip size to metal thickness
Cutting tip size determines the oxygen flow rate and kerf width. A size 0 tip cuts up to 1/4" steel. Size 1 handles 1/4" to 1/2". Size 2 handles 1/2" to 1". Size 3 handles 1" to 2". Size 4 handles 2" to 4". Using an oversized tip wastes gas and produces a rough cut edge. Using an undersized tip stalls the cut.
2
Set correct working pressures
For acetylene welding, oxygen pressure is typically 3-8 PSI and acetylene 3-5 PSI depending on tip size. For cutting, oxygen pressure ranges from 25-50 PSI (higher for thicker material) and acetylene remains at 3-8 PSI for the preheat flame. Never exceed 15 PSI on acetylene — above this pressure acetylene becomes unstable and can decompose explosively.
3
Choose between acetylene and propane fuel
Acetylene produces a hotter flame (5,720 degrees F) and is required for oxy-fuel welding and brazing. Propane is cheaper for straight cutting work but cannot weld. For shops that both cut and weld, acetylene is the standard. For dedicated cutting operations on thick plate, propane or propylene reduces fuel cost.
4
Regulator quality matters
Two-stage regulators deliver more consistent pressure than single-stage units, especially as the cylinder empties. For production cutting, two-stage regulators prevent pressure drift that affects cut quality. Harris and Victor offer industrial-grade two-stage regulators with 10-year diaphragm warranties.
5
Hose length and safety accessories
Standard hose length is 25 feet. For large fabrication shops or outdoor work, 50-foot hoses provide reach but increase gas pressure drop — compensate with slightly higher regulator settings. Always install flashback arrestors on both regulators. Use a friction striker, never a cigarette lighter, to ignite the torch.