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Cutting torch tip sizes by steel thickness
Complete Victor chart ↓Quick answer: For Victor Series 1 Type 101 acetylene tips, 1/4 in mild steel corresponds to size 00, 1/2 in to 0, 1 in to 2, and 2 in to 3. Other torch families use their own sizing charts. Victor source.
| Steel thickness | Tip size | Cutting O₂ reference |
|---|---|---|
| 1/4 in | 00 | 20–25 psig |
| 1/2 in | 0 | 30–35 psig |
| 3/4 in | 1 | 30–35 psig |
| 1 in | 2 | 40–45 psig |
| 2 in | 3 | 40–45 psig |
| 3 in | 4 | 40–50 psig |
| 4 in | 5 | 45–55 psig |
The table above is for Victor 1-101 on mild steel only. Pressures are manufacturer test conditions, not a substitute for confirming your complete torch, hose, regulator, and gas supply.
Find a tip for your steel thickness
Choose the brand/series and fuel first. The finder returns only published test thicknesses or range entries—not interpolated pressures.
Without JavaScript: refer to the Victor, Harris acetylene, or Harris propane tables below. Matching tip numbers across brands does not imply compatibility.
Victor 1-101 acetylene cutting-tip chart
Official Victor Professional Series 1 Type 101 operating references for mild steel, 1/8–5 in. Figures are transcribed from the manufacturer’s catalogue table with 25 ft of 1/4 in hose and regulator measurement for these tip sizes. Tip number alone does not select a safe pressure.
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Scroll the table horizontally on narrow screens; the steel-thickness column remains visible.
| 1/8 in | 3.175 | 000 | 0330-0003 | 20–25 | 3–5 | 20–25 | 3–5 | 28–32 | .04 |
|---|---|---|---|---|---|---|---|---|---|
| 1/4 in | 6.35 | 00 | 0330-0004 | 20–25 | 3–5 | 30–35 | 4–6 | 27–30 | .05 |
| 3/8 in | 9.525 | 0 | 0330-0012 | 25–30 | 3–5 | 55–60 | 5–8 | 24–28 | .06 |
| 1/2 in | 12.7 | 0 | 0330-0012 | 30–35 | 3–5 | 60–65 | 6–10 | 20–24 | .06 |
| 3/4 in | 19.05 | 1 | 0330-0005 | 30–35 | 3–5 | 80–85 | 8–13 | 17–21 | .07 |
| 1 in | 25.4 | 2 | 0330-0006 | 40–45 | 3–7 | 150–160 | 12–18 | 13–17 | .09 |
| 1 1/2 in | 38.1 | 2 | 0330-0006 | 40–45 | 3–7 | 150–160 | 12–18 | 13–17 | .09 |
| 2 in | 50.8 | 3 | 0330-0002 | 40–45 | 4–9 | 210–225 | 14–22 | 12–15 | .11 |
| 2 1/2 in | 63.5 | 3 | 0330-0002 | 45–50 | 4–10 | 225–240 | 16–26 | 10–13 | .11 |
| 3 in | 76.2 | 4 | 0330-0007 | 40–50 | 5–10 | 270–320 | 18–30 | 9–12 | .12 |
| 4 in | 101.6 | 5 | 0330-0008 | 45–55 | 5–12 | 390–425 | 22–34 | 8–11 | .15 |
| 5 in | 127 | 5 | 0330-0008 | 50–55 | 5–13 | 425–450 | 26–38 | 7–9 | .15 |
Source: Victor Series 1 Type 101 catalogue, p. 65. The separate preheat-O₂ pressure column in the manufacturer’s table applies to three-hose machine torches; for two-hose cutting torches, see the catalogue footnote. Cutting-O₂ flow and acetylene flow are separate from regulator pressure. This chart stops at tip size 5: sizes 6–8 have different hose and torch-capacity requirements and should be checked directly in the official document.
Cutting Torch Tip Size Chart — Victor Series 1 Type 101 only; pressure/flow values are manufacturer-specific, not universal.
Harris 6290 acetylene cutting-tip size chart
The following is the Harris 6290 single-piece acetylene chart for clean steel. Ranges are published cutting-depth bands, not guarantees for every equipment configuration. The Harris 6290-AC two-piece heavy-preheat family uses a different table; its tip numbers and pressures should not be combined with these values.
| Steel thickness | 6290 size | Cut O₂ reference | Acetylene reference | Orifice drill |
|---|---|---|---|---|
| Light gauge–3/16 in. | 000 | 15–20 psig | 5–15 psig | #68 |
| 3/16–3/8 in. | 00 | 20–25 psig | 5–15 psig | #64 |
| 3/8–5/8 in. | 0 | 35–40 psig | 5–15 psig | #60 |
| 5/8–1 in. | 1 | 35–40 psig | 5–15 psig | #56 |
| 1–2 in. | 2 | 40–45 psig | 5–15 psig | #52 |
| 2–3 in. | 3 | 45–50 psig | 5–15 psig | #48 |
| 3–6 in. | 4 | 50–75 psig | 10–15 psig | #42 |
For 6290 acetylene tips, use the Harris manufacturer chart for the full torch and equipment requirements. The upper end of its acetylene reference ranges is the OSHA 15 psig limit, not a default setting or recommendation to operate at the limit.
Harris 6290-NX propane / natural-gas tip chart
Harris 6290-NX is a different tip family designed for propane or natural gas. It must not be substituted for 6290 acetylene tips solely because a size number or cutting thickness overlaps. Its fuel-gas pressure specification depends on whether the torch uses low-pressure or equal-pressure operation.
| Steel thickness | 6290-NX tip | Cut O₂ reference | Fuel pressure | Orifice drill |
|---|---|---|---|---|
| Light gauge–3/16 in. | 000NX | 15–30 psig | Mixer-dependent¹ | #68 |
| 3/16–3/8 in. | 00NX | 20–30 psig | Mixer-dependent¹ | #64 |
| 3/8–5/8 in. | 0NX | 30–40 psig | Mixer-dependent¹ | #60 |
| 5/8–1 in. | 1NX | 35–50 psig | Mixer-dependent¹ | #56 |
| 1–2 in. | 2NX | 40–55 psig | Mixer-dependent¹ | #52 |
| 2–3 in. | 3NX | 45–60 psig | Mixer-dependent¹ | #48 |
| 3–6 in. | 4NX | 50–75 psig | Mixer-dependent¹ | #42 |
| 6–8 in. | 5NX | 65–80 psig | Mixer-dependent¹ | #35 |
| 8–12 in. | 6NX | 70–90 psig | Mixer-dependent¹ | #30 |
¹ Harris lists fuel at 4 oz/in² to 2 psig for low-pressure systems and 5–15 psig for equal-pressure systems. Identify the torch/mixer before interpreting the correct column. These are not alternative settings to try. Harris chart.
How to choose the correct cutting torch tip size
- Identify torch and attachment. Record the manufacturer, cutting attachment/torch model, compatible seat and tip series. A size “1” or “2” without a series does not establish compatibility.
- Confirm the fuel gas. Acetylene and propane/natural gas use different preheat arrangements and published conditions. Choose the corresponding chart, not the nearest numerical match.
- Identify the metal. These reference charts are for ordinary mild steel. Standard oxy-fuel flame cutting is not a general chart for stainless steel, aluminum or alloys with substantially different oxidation behavior.
- Measure the workpiece thickness. Use the listed Victor test thickness or Harris published thickness band; where two Harris bands meet, confirm the correct option with the manufacturer.
- Review the complete manufacturer guidance. Check oxygen supply flow (SCFH), fuel supply capacity, hose diameter/length, regulator model, approved safety devices, and tip condition before operation.
- Use the equipment instructions. A web chart is for identifying references and cannot approve an operating setup or replace trained oxy-fuel procedures.
Victor 1-101 lists size 0 at 1/2 in. Harris 6290 includes 1/2 in in its size 0 depth band, and 6290-NX includes it in the size 0NX band. Identical numerals do not mean the tips physically interchange or share gas pressures.
What the cutting tip, orifice and seat do
A cutting tip has a central cutting-oxygen passage and surrounding preheat passages. The contact/seat geometry at the torch end must match the cutting attachment; it is not defined by tip-size number alone. The preheat flame heats the steel, while the cutting-oxygen jet supports the oxidation and expels material. The precise passage layout and compatible fuel depend on tip family.
Cutting oxygen pressure, flow (SCFH) and hose limitations
Cutting oxygen pressure is not the same thing as cutting oxygen flow. Pressure figures describe a manufacturer’s stated test conditions; flow figures describe the gas quantity the supply must support. A system that can show a regulator pressure while idle may still fail to provide adequate flow during cutting.
Victor’s primary 1-101 catalogue specifies pressures measured at the regulator using 25 ft of 1/4 in hose through tip size 5. For size 6 and above, it specifies a 25 ft × 3/8 in hose, with additional torch-capacity guidance. This page deliberately does not apply the smaller-tip hose conditions to larger tips. Victor catalogue footnotes.
The manufacturer’s preheat-oxygen figures apply to a three-hose machine cutting torch; a two-hose torch does not use an independent preheat-oxygen regulator in the same way. Consult the exact equipment manual for hose layout, pressure measurement, protective devices, inspections and gas-flow requirements. Do not estimate values from adjacent thickness rows or another fuel family.
In the United States, OSHA 29 CFR 1910.253 limits acetylene utilization to a maximum of 15 psig. The approved-manifold exception in that regulation concerns certain piping, not permission to operate a torch above the utilization limit. Fifteen psig is a maximum use-pressure restriction, not a preferred operating pressure. Manufacturer guidance may also restrict acetylene-cylinder withdrawal rates: verify current supply requirements when choosing large tips. OSHA source.
Acetylene versus propane and other materials
Oxy-acetylene and oxy-propane can both be used for appropriate mild-steel cutting applications, but their tip preheat designs, torch mixers and manufacturer charts differ. The Harris 6290 and 6290-NX tables above illustrate that a similar nominal size or thickness band may have different oxygen references and fuel-system assumptions.
The charts do not establish oxygen-fuel cutting capability for stainless steel, aluminum, coated containers, unknown scrap, pressure vessels, or previously used chemical/fuel tanks. Confirm the workpiece, preparation requirements, fire prevention plan and approved cutting process. Keep combustible hazards, ventilation, fire watches and protective equipment under the facility’s work authorization and applicable requirements.
For a propane/natural-gas system, determine whether the torch is designed for low-pressure injector or equal-pressure operation before consulting its pressure column. Using an acetylene tip or gas chart as a substitute is inappropriate even if the tip seems to attach mechanically.
Cut quality problems: what to inspect before changing a tip
| Observed problem | Verify before resuming |
|---|---|
| Crooked or irregular kerf | Cutting oxygen orifice damage/contamination, tip alignment, material scale and correct family. |
| Pressure drops during cutting | Supply and regulator capacity, hose configuration, restrictions and properly sized components. |
| Excessive slag or rough cut | Correct manufacturer chart, travel-speed requirements, tip condition and workpiece suitability. |
| Unstable flame, popping or sustained backfire | Stop using the equipment and follow manufacturer shutdown and inspection procedures before reuse. |
| Tip does not seat firmly | Approved model/seat compatibility and component condition; do not force or modify a tip. |
These are checks to discuss with trained personnel, not a substitute for an operating or maintenance procedure. A tip that is damaged, leaking, or the wrong fit should not be used. Harris cutting-quality guidance.
Cutting Torch Tip Size Chart FAQs
What size cutting torch tip do I need for 1/2-inch steel?
Victor Series 1 Type 101 acetylene lists size 0 at 1/2 in mild steel. Harris 6290 acetylene and Harris 6290-NX propane/natural gas list 1/2 in within their respective size 0 and 0NX bands. Use the chart for the actual brand, fuel, torch and mixer, rather than assuming interchangeability.
Which Victor tip is listed for 1/4-inch steel?
Victor 1-101 lists size 00, part number 0330-0004, for the 1/4-inch reference row. The manufacturer’s stated equipment and pressure basis still apply.
How do I read cutting torch tip size numbers?
Identify the brand, compatible torch model, complete tip series and fuel designation first. Within the Victor 1-101 family, sizes 000, 00, 0, 1, 2, 3, 4 and 5 correspond to different manufacturer reference applications. The number alone does not establish metal thickness or operating pressure across manufacturers.
Are Victor, Harris and Smith cutting tips interchangeable?
No universal interchangeability can be assumed. Confirm the exact seating geometry, cutting attachment, tip series and manufacturer-approved compatibility even when nominal sizes look similar.
Can I use an acetylene tip size chart for propane?
No. Select a tip and chart expressly rated for propane/natural gas, such as the named Harris 6290-NX family, and confirm the exact torch/mixer and fuel pressure basis.
What is the difference between cutting oxygen pressure and oxygen flow?
Pressure is expressed in psig, while flow or consumption is expressed in SCFH. The manufacturer gives both because enough pressure with insufficient gas-flow capacity can still produce poor performance.
What are cutting speed and kerf width?
Cutting speed is the linear travel rate of the cut, typically inches per minute. Kerf width is the width of material removed by the cutting process. Both depend on the named tip, thickness and conditions; the Victor chart reports specific example ranges.
What if my metal thickness is between published rows?
Do not interpolate an oxygen or fuel pressure from adjacent published rows. Use the current manufacturer tip-selection guidance for the intended thickness, material, fuel and equipment.
Is 15 psi the normal acetylene operating pressure?
No. OSHA’s 15 psig acetylene use-pressure rule is a maximum restriction, not a normal set point. Most Victor acetylene references shown on this page are below it.
Does the chart work for stainless steel or aluminum?
No. The published examples are based on mild-steel oxygen-fuel cutting. Select a process and manufacturer data suited to other metals rather than applying mild-steel cutting-tip values.
Sources and data basis
Checked October 29, 2026. All numerical chart data is reproduced as a factual reference from the named manufacturer family; test conditions and family restrictions matter. The page does not calculate operating set points, approve interchangeability or offer pressure interpolation.
- Victor Technologies — Series 1 Type 101, Professional acetylene cutting tips (catalogue p. 65)Primary Victor manufacturer table. Includes test thickness, tip size, part number, oxygen/fuel pressures and flows, speed, kerf and hose notes.
- ESAB / Victor — Type 101 acetylene cutting tipsProduct family and part-number cross-check. For reference consistency, this page uses the single-row data in the cited Victor catalogue, rather than combining multiple alternative entries shown on the product site.
- Harris Products Group / Lincoln Electric — Cutting Tip Charts (Rev. E, March 2017)Harris 6290 acetylene and 6290-NX propane/natural-gas bands and pressure references; separate family tables.
- OSHA — 29 CFR 1910.253, Oxygen-fuel gas welding and cuttingAcetylene 15 psig pressure maximum and other workplace safety requirements.