A Seminar Report On

EQUIPMENT USED IN OXY-ACETELEN WELDING

Submitted by

PATIL KRUNAL R. EN.NO. 106550319004

Department Of Mechanical Engineering At VALLBHBUDHI POLYTECHNIC NAVSARI

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ACKNOWLEDGEMENT
I take this privileged opportunity to express our hearty thanks to you for providing me and guiding me such a nice opportunity of learning and developing myself as better mechanical professional. I would also like to thank STAFF MEMBERS for helping out me during the entire seminar procedure conducted during the semester. I would thank to express my deep feeling of gratitude to the under mentioned faculties for their assistance, guidance and inspiration before and through the seminar. I also indebted to sir for their readiness to provide all resources for making this seminar successfully completed well within time. I would like to thank Vallbhbudhi Polytechnic, Navsari for providing me such a good opportunity to represent the seminar. As far as my work is concerned I have tried to make very clear the information I am providing and have tried best to represent myself in this seminar.

Thanking you, Krunal Patil

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INDEX
() ACKNOWLEDGMENT Chapter 1 INTRODUCTION Equipments of oxyacetylene welding WELDING TORCH 2.1 Types of torches A. Working of low pressure blowpipe B. Working of high pressure blowpipe 2.2 Welding nozzles or tips 2.3 Care of welding tips 2.4 Gas lighter PRESSURE REGULATOR 3.1 Single stage pressure regulator 3.2 Double stage pressure regulator 3.3 Difference bet acetylene-oxygen regulator CONCLUSION 2 page no. 4 5 5 6 6 8 9 9 10 10 11 14 15

Chapter 2

Chapter 3

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1. Introduction
The main equipment used in oxyacetylene welding is flame. Torch is only flame producing equipment. There are too many types of equipment that are used in oxyacetylene welding. Following are main equipment used in oxyacetylene welding: 1) 2) 3) 4) 5) 6) 7) 8) Welding torch or blowpipe Pressure regulators Hose and hose fittings Gas cylinders Goggles, Hand gloves and apron Welding rod and wire brush Spark lighter Flux

Here well only study about first two equipments. 1. Welding torch or blowpipe 2. Pressure regulator

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2. WELDING TORCH
Oxygen and the fuel gas having been reduced in pressure by the gas regulators are fed through suitable hoses to a welding torch which mixes and controls the flow of gases to the welding nozzle or tip where the gas mixture is burnt to produce a flame for carrying out gas welding operation.

Oxygen and the fuel gas having been reduced in pressure by the gas regulators are fed through suitable hoses to a welding torch which mixes and controls the flow of gases to the welding nozzle or tip where the gas mixture is burnt to produce a flame for carrying out gas welding operation.

2.1
1) 2) 3) 4)

TYPES OF TORCH:

Torches are broadly classified as under. Injector torch Rose-bud torch Cutting torch Welding torch

In this oxyacetylene welding torch have only two types.

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1. Injector type (Low pressure torch) 2. Positive or equal pressure type (High pressure torch)

High pressure blowpipes or torches are used with (dissolved) acetylene stored in cylinders at a pressure of 8 bar. Low pressure blowpipes are used with acetylene obtained from an acetylene generator at a pressure of 200 mm head of water (approximately 0.02 bar).

(A)

WORKING OF A LOW PRESSURE BLOWPIPE: It is termed

as a low pressure blowpipe because it can be operated at low acetylene pressures; it is frequently used with acetylene generators. As acetylene is of low pressure, it is necessary to use oxygen at a high pressure (2.5 bar). The oxygen enters the mixing chamber through a passage located in the centre of the torch. The oxygen passage is surrounded by the one carrying the acetylene. The high pressure oxygen passes through a small opening in the injector nozzle, enters the mixing chamber and pulls (or draws) the acetylene in after it. An advantage of low pressure torch is that small fluctuations in the oxygen supplied to it will produce a corresponding change in the amount of acetylene drawn; thereby making the proportions of the two gases constant while the torch is in operation.

(B)

WORKING OF A HIGH PRESSURE BLOWPIPE:

In this type of blowpipe both the oxygen and acetylene are fed to the blow pipe at equal pressures and the gases are mixed in a mixing chamber prior to being fed to the nozzle tip. The equal pressure or high pressure type of blowpipe is the one most generally used because (i) It is lighter and simpler. (ii) It does not need an injector.
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(iii) In operation, it is less troublesome since it does not suffer from backfires to the same extent.

To change the power of the welding torch, it is only necessary to change the nozzle tip (size) and increase or decrease the gas pressures appropriately.

(1) Head of low pressure torch

(2) high pressure welding torch

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2.2 WELDING NOZZLES OR TIPS :

Depending upon the design of the welding torch (or the blow pipe) the interchangeable nozzles may consist of: (i) Either, a set of tips which screw onto the head of the blowpipe, (ii) As a set of gooseneck extensions fitting directly onto the mixer portion of the blowpipe. The welding nozzle or tip is that portion of the torch which is located at the end of the torch and contains the opening through which the oxygen and acetylene gas mixture passes prior to ignition and combustion. A welding nozzle enables the welder to guide the flame and direct it with the maximum ease and efficiency. The following factors are important in the selection of appropriate welding nozzle: (i)The position of the weld. (ii) The type of joint. (iii) Job thickness and the size of welding flame required for the job. (iv) The metal/alloy to be welded. To provide for different amounts of heat, to weld metals of different thicknesses, welding tips are made in various sizes. The size of a welding tip is determined by the diameter of the opening or orifice in the tip. As the orifice size increases, greater amounts of the welding gases pass through and are burnt to supply a greater amount of heat. The choice of the proper tip size is very important to good welding. A chart giving sizes of tips for welding various thicknesses of metal along with oxygen and acetylene pressures used is generally provided by the manufacturers.

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2.3 CARE OF WELDING TIPS:

(i) All welding tips are made of copper and may be damaged by careless handling. (ii) Nozzles should never be dropped or used for moving or holding the work. (iii) Nozzle seat and threads should be absolutely free from foreign matter in order to prevent any scoring when tightening on assembly. (iv) Nozzle orifice should only be cleaned with tip cleaners specially designed for this purpose

2.4 GAS LIGHTER:

A gas (spark) lighter provides a convenient, safe and inexpensive means of lighting the torch. Match sticks should never be used for this purpose because the puff of the flame produced by the ignition of the acetylene flowing from the tip is likely to burn the welder's hand. Spark lighters are constructed from flint and steel.

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3. PRESSURE REGULATOR

The pressure of the gases obtained from cylinders/generators is considerably higher than the gas pressure used to operate the welding torch. The purpose of using a gas pressure regulator is, therefore (i) to reduce the high pressure of the gas in the cylinder to a suitable working pressure, and (ii) to produce a steady flow of gas under varying cylinder pressures.

A pressure regulator is fitted with two pressure gauges. One indicates the gas pressure in the cylinder and the other shows the reduced pressure at which the gas is going out. A pressure regulator is connected between the cylinder/generator and the hose leading to welding torch.

Gas pressure regulators may be classified as: 1) Single stage Regulator 2) Two stage Regulator.

3.1 SINGLE STAGE REGULATOR:

In single stage pressure regulator reduction of pressure from the cylinder pressure to the welding pressures takes place. As shown in figure (1) the pressure in the hoses in controlled by applying pressure to the spring

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through an adjusting screw. The spring applies pressure to a flexible rubber diaphragm which is connected to the (high pressure) valve.

FIGURE (1)
The gas from the cylinder flows past the open valve enters the valve chamber and builds up pressure on the diaphragm. When the pressure inside the valve chamber is slightly greater than the spring tension supporting the diaphragm, the valve closes the high pressure inlet, and stops the flow of any more gas into the valve chamber. The gas thus trapped inside the valve chamber is allowed to flow out through the low pressure outlet into the welding hose, which, in turn, relieves the chamber pressure, opens the valve again and the process repeats.
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 A single stage regulator is all that actually is needed for both oxygen regulation and acetylene regulation for oxyacetylene welding. Single stage regulators may be classified as follows depending upon the method used to close the seat mechanism and thereby control the gas flow: a. Direct or nozzle type b. Inverse or steam type In (a) the seat is forced to close against the gas flow (away from the nozzle) by the incoming high pressure gas. In (b) the incoming high pressure gas forces the seat toward the nozzle in the direction of the gas flow. A single stage regulator tends to freeze in cold weather. This is because a sudden expansion and resulting drop in initial pressure causes rapid cooling of the gas involved. The moisture present in the gas, thus, results in the formation of ice on or near the regulator nozzle which causes irregular seating of the seat on the nozzle and therefore substantial pressure fluctuations.

3.2

DOUBLE STAGE REGULATOR:

In double stage pressure regulator reduction of pressure takes place in two

stages. The principle of pressure reduction in a two stage regulator is exactly the same as in a single stage regulator. But the pressure is reduced in two stages instead of one, using two diaphragms and two control valves, so that the pressure reduction ratio is less abrupt. The gas pressure is automatically reduced by the first, preset stage, the second stage of pressure reduction being controlled by the welder by way of the adjustable screw and spring valve. A two stage regulator is used with cylinders and manifolds A two stage regulator may consist of: a. two inverse type stages b. two direct type stages c. First direct type stage and second inverse type stage.
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FIGURE (2)
Two stage regulators of mixed stage type are the most common. The same situation occurs in the first reduction stage of a two stage regulator; the second stage is not sufficiently affected to produce a noticeable pressure disturbance.

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3.3

DIFFERENCE BET ACETYLENE REGULATOR & OXYGEN REGULATOR :

Sr.no Acetylene Regulator 1. The cylinder and hose connections have left handed threads on the acetylene regulator. Acetylene connection nuts have chamfers or grooves cut in them. Color band on acetylene regulator in maroon or red. The inlet or high pressure gauge on the regulator reads up to 8 bar. The outlet or low pressure gauge on the regulator reads up to 1 bar.

Oxygen Regulator There are right hand threads in this case. Nuts are plain, i.e., with no chamfer or grooves. It is either blue or black on the oxygen regulator. The inlet or high pressure gauge on the regulator reads up to 100 bar. The outlet or low pressure gauge on the regulator reads up to 4.8 bar.

2. 3. 4.

5.

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CONCLUSION
From this seminar I briefly studied about construction and working of welding torch and pressure regulator and it increased my knowledge about welding. Its overall conclusion is that welding torches and pressure regulators are really useful for welding and efficient.

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