3.

0 OXY-ACETYLENE WELDING (OAW)

Prepared by: Shahfuan Hanif A A. Hamidi Fabrication and Joining Section University Kuala Lumpur

Ou e Outline
3.1. 3 1 3.2. 33 3.3. Introduction I t d ti Principle of operation Equipments
3.3.1 3.3.2 3.3.3 3.3.4 Oxygen & acetylene cylinders Regulator Regulator Hoses Torch, Tip & Welding Rod

3.4. 3.5 36 3.6

Fuel Gases Flames Ad Advantages and d Limitations Li i i

3.1: Introduction

OAW is a manual process in which the welder must personally control the torch movement and filler rod application. Cylinders C linders contain oxygen o gen (2250Psi) and acetylene acet lene gas (225psi) at extremely high pressure. OFW or OAW has many important uses: Welding, Cutting, hardening, tempering, bending, forming, preheating, postheating, brazing etc. Its major industrial applications are in the field of maintenance and repair, the welding of small- diameter pipe, and for light manufacturing.

3.2 Principle of operation

The oxyacetylene welding process uses a combination of oxygen(O2) and acetylene(C2H2 ) gas to provide a high temperature flame(6300 F or 3482 C). C2H2 + O2 = 2CO + H +heat Filler metal is added and solidify to produce the weld joint

3.2 Principle of operation (cont)

When welding any metal metal, the appropriate filler material must be selected and used. The filler metal must m st match the composition of the base metal to be welded and normally contains deoxidizers to aid in producing sound welds. The oxyacetylene welding process is normally used for welding thinner materials up to in. (6.4 mm) thick.

3.3 Equipments

3.3 Equipments (cont)

The apparatus and equipment employed for oxyacetylene welding are: (1) welding torch and tips, (2) oxygen and acetylene hose, (3) oxygen and acetylene regulators, (4) oxygen cylinder, (5) acetylene cylinder.

3.3 Equipments (cont)

3.3.1

Oxygen cylinders

Oxygen is stored within cylinders of various sizes and pressures ranging from 2000- 2640 PSI. (Pounds Per square inch) . Oxygen O gen c cylinders linders are forged from solid armor plate steel. steel No part of the cylinder may be less than 1/4 thick. Cylinders are then tested to over 3,300 PSI using a (NDE) hydrostatic pressure test.

3.3.1

Oxygen cylinders (cont)

3.3.1

Acetylene cylinders (cont)

Cylinders are filled with a very porous substance monolithic monolithic filler filler to help prevent large pockets of pure acetylene form forming. Cylinders C linders have ha e safety safet (Fuse) (F se) plugs pl gs in the top and bottom designed to melt at 212 F (100 C). Safety valves and plug in oxygen and acetylene cylinder is purpose to prevent the cylinder burst from overpressure.

3.3.2

Regulator

There are two types of regulators: 1. Single-stage regulator 2. Two-stage regulator. The single-stage regulator reduces the cylinder pressure of the gas to a working pressure in one step. Single-stage regulators must be re-adjusted from time to time to maintain the required working pressure. The gas pressure in the cylinder decreases gradually as gas is withdrawn. Single-stage regulators are less expensive than two-stage regulators and are more popular

Single-stage g g regulator g

3.3.2

Regulator (cont)

The two-stage regulator makes the reduction of pressure in two steps. steps The first step reduces the cylinder pressure to an intermediate press re The second step red pressure. reduces ces this intermediate pressure press re to the desired working pressure. The two-stage regulator provides more accurate regulation and eliminates the need to re-adjust the regulator as the pressure in the supply tank is reduced. Regulators have two pressure gauges: one shows the pressure of the gas inside the cylinder; the other shows the working pressure that is b i supplied being li d to the h torch. h

TWO-STAGE REGULATOR

The different between Acetylene y and Oxygen yg fitting g

Regulator g Pressure Settings g

The maximum Th i safe f working ki pressure f for acetylene t l is 15 PSI !

Check Valves & Flashback Arrestors

Check valves allow gas flow in one direction only Flashback arrestors are designed to eliminate the possibility of an explosion at the cylinder. cylinder Combination Check/ Flashback Valves can be placed at the torch or regulator.

3.3.3

Regulator Hose

Hoses are fabricated from rubber Oxygen hoses are green in color and ha e right hand thread. have thread Acetylene hoses are red in color with left hand thread. Left e hand a d threads eads can ca be identified de ed by a grove in the body of the nut and it may have ACET stamped on it

3.3.4

Torch

Two basic types of torches, torches 1. medium- pressure torch (most popular) 2 2. low pressure or injector low-pressure type. When using the mediumpressure torch, both oxygen and acetylene are supplied at approximately pp y the same pressure, which may vary from 1 to 10 psi depending on the size of the tip being used. The two gases are mixed i d together t th in i the th mixing chamber in the torch handle

3.3.4

Tip

3.3.4

Welding Rod

The American Welding Society provides a specification covering welding rods or filler metal used for the oxyacetylene or oxyfuel gas welding process. The specification number has the prefix letter R. This is followed by y two or three digits, g , 45, , 60, , 65, , or 100, , which designate g the approximate tensile strength in ksi (1000 psi).

3.4 Fuel Gases

Why acetylene?

3.5 Flame

Three distinct type of oxy-acetylene flames, flames usually termed:

1. 2. 3.

Neutral Carburizing (or excess acetylene) Oxidizing (or excess oxygen )

The type of flame produced depends upon the ratio of oxygen to acetylene in the gas mixture which leaves the torch tip.

3.5 Flame (cont)

The neutral flame is produced when the ratio of oxygen to acetylene, acetylene in the mixture leaving the torch, is almost exactly one-to-one. Its termed neutral because it will usually have no chemical effect on the metal being g welded. It will not oxidize the weld metal The excess acetylene flame is created when the proportion of acetylene in the mixture is higher than that required to produce the neutral flame. Used on steel, it will cause an increase in the carbon content of the weld metal. The oxidizing flame results from burning a mixture which contains more oxygen than required for a neutral flame. It will oxidize or burn some of the metal being welded. burn

3.5 Flame (cont)

Pure Acetylene and Carburizing Flame profiles

3.5 Flame (cont)

Neutral and Oxidizing Flame Profiles

3.6 Advantages

The equipment is very portable. portable It is relatively inexpensive it can be used in all welding positions the pool is visible to the welder. The equipment Th i t is i versatile. til It can be b used d for f welding, ldi brazing, b i soldering, and with proper equipment, for flame cutting. It can also be used as a source of heat for bending, forming, straightening, hardening, and so on.

3.6 Limitations

The equipment for oxyacetylene welding is the least expensive of all. all It is one of the slowest processes due to the heat transfer and temperat re involved. temperature in ol ed For this reason oxy acetylene welding has been largely supplanted for most manufacturing operations.