GAS WELDING PROCESS AND EQUIPMENT

OXY- FUEL GAS WELDING:

1. Refers to a group of welding processes that use as their heat
source, the FLAME produced by the combustion of a FUEL GAS
and OXYGEN.
2. Still popular for many applications because of its PORTABILITY
and LOW COST of investment.
3. ACETYLENE (C₂ H₂) is mostly the principal gas fuel used.
4. Combination of ACETYLENE (C₂ H₂) and OXYGEN (O₂) by means
of a welding torch produces temperatures of up to 5850 °F
(3250 °C) in a two stage reaction:-

a) FIRST STAGE: C₂ H₂ + O₂ = 2CO + H₂ ( Occurs near the tip of the torch)

b) SECOND STAGE: 2CO + O₂ = 2CO₂ ( Occurs beyond the first combustion zone)

H₂ + ½ O₂= H₂O
 THE FLAME:

1. The two stage combustion process

produces a flame that has two
distinct regions.
2. Maximum temperature is produced
near end of the inner cone, where
FIRST STAGE of combustion is
completed. (Welding temperature
position).
3. Outer envelope serves to pre-heat
the metal and at the same time
provides shielding from OXIDATION
since most of the surrounding
oxygen is consumed in this
secondary combustion.
 TYPES OF FLAMES
NEUTRAL FLAME
• Addition of little more oxygen give a bright whitish cone surrounded by the transparent
blue envelope is called Neutral flame (It has a balance of fuel gas and oxygen) (32000c or
58000 F)
• Ratio (Oxygen : Acetylene) = 1:1 or 1.15:1 (All reactions are carried to completion)
• Most welding is done with neutral flame.
• Used for welding steels, aluminum, copper and cast iron

CARBURIZING FLAME
• Excess fuel than Oxygen produces Carburizing flame, also called reducing flames.
• Metal remains protected from oxidation.
• Used for welding Monel (nickel-copper alloy), high carbon steel, some alloys of steel, etc.
• (30000c or 55000 F )

OXIDIZING FLAME
• If more oxygen is added, the cone becomes darker and more pointed, while the envelope
becomes shorter and more fierce is called Oxidizing flame
• Has the highest temperature about 36000c or 60000 F
• Ratio is 1.5 to 1
• Used for welding brass and brazing operation
 Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting
operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing flame.
Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting
operations:
(a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing flame.
 MIXTURE OF OXYGEN & ACETYLENE GAS

1. It is a highly EXPLOSIVE mixture. Care should be

taken to avoid mixing gasses improperly.

2. Acetylene fittings have LEFT hand threads and

3. Oxygen fittings have RIGHT hand threads, to

prevent improper installation of connection.
 WELDING PROCESS
1. Almost all oxy-fuel gas welding is fusion welding.
2. The metals to be joined are simply melted where a weld is
required and no pressure is required.
3. Because a slight gap often exists between pieces being joined,
FILLER METAL can be added (WIRE or ROD)
4. Available in tensile strength or in composition to match the base
metal.
5. Welding rod standard sizes: 1/16 to 3/8 in dia. Length: 24-26 inch.
6. FLUXES (Borax) may be used to clean the surfaces and remove
OXIDES for a better weld.
7. In addition, gaseous shield produced prevents further oxidation,
and the slag produced solidifies and protects the weld a it cools.
8. Flux can be added as a powder, welding rod can be dipped in a flux
paste, or the rod can be pre-coated.
 OXYACETYLENE GAS WELDING

The principle of the oxyfuel-gas welding operation.

Oxyfuel gas welding

10
 LIMITATIONS OF OXY-GAS WELDING

1. Since heat source is not concentrated, large area of

metal is heated and distortion may occur.

2. That is why in production application, GAS

WELDING has largely been replaced by ARC
WELDING.
 GAS WELDING
1. Sound weld is obtained by selecting proper size of flame, filler
material and method of moving torch

2. The temperature generated during the process is 33000c

3. When the metal is fused, oxygen from the atmosphere and the
torch combines with molten metal and forms oxides, results
defective weld

4. Fluxes are added to the welded metal to remove oxides

5. Common fluxes used are made of sodium, potassium, lithium and

borax.

6. Flux can be applied as paste, powder, liquid, solid coating or gas.

 GAS WELDING EQUIPMENT
1. Gas Cylinders
Pressure
Oxygen – 125 kg/cm2
Acetylene – 16 kg/cm2
2. Regulators
Working pressure of oxygen 1 kg/cm2
Working pressure of acetylene 0.15 kg/cm2
Working pressure varies depends upon the
thickness of the work pieces welded.
3. Pressure Gauges
4. Hoses
5. Welding torch
6. Check valve
7. Non return valve
OXY-ACETYLENE WELDING
WELDING TORCH

GAS CUTTING
TORCH
 GAS CUTTING

Automatic Gas Cutting Manual Gas Cutting

 WELDING/CUTTING HAZARDS

POTENTIAL HAZARDS

1. Fires may start by hot materials igniting nearby

combustibles.

2. Burns to the operator may occur if unprotected

skin comes into contact with the extremely hot
work.
 WELDING/CUTTING HAZARDS
POTENTIAL HAZARDS CONT.:
1. Metal fumes from vaporizing of the work with the extremely
hot arcs may be inhaled into the worker’s lungs.

2. Certain metals and metal oxide fumes, including zinc,

cadmium and beryllium, produce serious illnesses when
inhaled.

3. Fluxes used with welding to create inert atmospheres at the

point of the weld also present inhalation hazards.

4. All welding and cutting must have adequate ventilation to

protect the person doing the welding and those working
around the welding area.
 METAL TREATMENT

1. Preheating the weld zone – reduces energy input, cooling rates in

the weld, reduces differential shrinkage, residual stresses, and
distortion.
2. Post-welding heat treatment of the entire welded structure:
a. Stress-relief anneal reduces residual stresses to acceptable
level.
b. Normalizing a steel wipes out most undesirable effects of
welding.
c. Full heat treatment (quenching and tempering of steels)

3. Peening (hammering or rolling) of weld bead improves the

strength of welds.
 GAS CUTTING

1. Ferrous metal is heated in to red hot condition (15000 F) and a jet of

pure oxygen is added to the torch and projected onto the surface,
which (iron) rapidly oxidizes
2. Oxides having lower melting point than the metal, melt and are blown
away by the force of the jet, to make a cut
3. Fast and efficient method of cutting steel to a high degree of accuracy
4. Torch is different from welding
5. Cutting torch has preheat orifice and one central orifice for oxygen jet

PIERCING and GOUGING are two important operations

6. Piercing, used to cut a hole at the centre of the plate or away from the
edge of the plate
7. Gouging, to cut a groove into the steel surface
 OXYACETYLENE TORCH

The acetylene valve is opened first; the

gas is lit with a spark lighter or a pilot
light; then the oxygen valve is opened
and the flame adjusted.

Basic equipment used in oxyfuel-gas welding. To ensure correct connections, all

threads on acetylene fittings are left-handed, whereas those for oxygen are right-
handed. Oxygen regulators are usually painted green, and acetylene regulators
red.
 WELDING TORCH TIP
1. The tip size ( or orifice
diameter) of the torch can
be varied to control the
shape of the flame inner
cone and flow rate of
oxygen.
2. Large diameters allow
greater flow of gases and
attain high temperatures
and gas velocities.
3. Large tips are used for
welding thicker metals.
• Heat Affected Zone (HAZ) is a part of the base
metal that is not melted during the fusion welding
but is heated to an elevated temperature (below
the melting temperature of the concerned material)
before cooling down to room temperature. HAZ is
located surrounding the weld metal. HAZ does not
contain filler metal. Base metal within the HAZ
undergoes heating and subsequent t cooling;
however, no phase change occurs (that means HAZ
always remains in solid phase)
The end of this lecture