OXY-ACETYLENE WELDING

Principals and Equipment: Equipment: A fusion welding process A manual process System consists of compressed gas cylinders, gas pressure regulators, hoses, and a welding torch Required heat is provided by oxy-acetylene flame Uses oxygen and acetylene gases Flame temperature is 3200 C A special torch is needed Filler material is fed externally

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN

OXY-ACETYLENE WELDING
Consumables: Consumables: Oxygen gas Acetylene gas Filler wires Nonferrous metals and cast iron require flux

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN

OXY-ACETYLENE WELDING
OXYGEN GAS & OXYGEN CYLINDER Oxygen ensures the combustion of acetylene. Because small percentages of contaminants have a noticeable effect on combustion efficiency, a purity of 99,5% and higher is needed. In normal consumption, standard cylinders are used. In higher consumptions permanent supply systems are used (with joined banks of cylinders or liquid oxygen cylinder)

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN

OXY-ACETYLENE WELDING
ACETYLENE GAS AND ACETYLEYE CYLINDER A hydrocarbon gas. Chemical formula is C2H2. Above 1,5 bars pressure acetylene is unstable; it decomposes exothermically even if the absence of oxygen. In pressurized cylinders acetylene is dissolved in acetone. Cylinders must be stored and used in upright position. Withdrawal rate from a cylinder is maximum 500 to 700 liters per hour.

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN

OXY-ACETYLENE WELDING
REGULATORS Regulators are used to reduce the gas pressure inside the cylinder to the working pressure. Working pressure is selected according to the used torch tip.

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN

OXY-ACETYLENE WELDING
WELDING TORCH Welding torch is used to mix the gases and burn in front of the tip. There are oxygen and acetylene valves on the torch. These enable the adjustment of the gas flow rates. Flow rates depend on the used tip size.

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN

OXY-ACETYLENE WELDING
WELDING FLAME Combustion takes place in two stages: First stage reaction takes place in the inner cone of the flame and uses the oxygen supplied from the cylinder:
2C2H2 + 2O2 4CO + 2 H2

Second stage uses the oxygen from the surrounding air. This is the outer envelope of the flame:
4CO + 2H2 + 3O2 4CO2 + 2H2O

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN

OXY-ACETYLENE WELDING
WELDING PARAMETERS Torch tip size. Flame adjustment:
Neutral Excess acetylene Excess oxygen

Working technique:
Leftward (forehand) Rightward (backhand)

Welding speed Filler wire type and size. Welding position.

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN

OXY-ACETYLENE WELDING
ADVANTAGES The welder has considerable control over the temperature of the metal in the weld zone. The welder has control over filler-metal deposition rate. Clearly view the weld area. Heat can be applied preferentially to the base metal or the filler metal without removing either from the flame envelope. No need to electricity. Equipment is low cost and usually portable. Thin metals with poor fit-up can be welded. Small diameter pipes can be welded. Same equipment can be used for preheating, postheating and brazing applications.

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN

OXY-ACETYLENE WELDING
DISADVANTAGES A wide heat affected zone. Slow process. Gases are expensive. Workpiece thickness is limited up to 6 mm. Depends on the welder skill.

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN

OXY-ACETYLENE WELDING
APPLICATION AREA Most ferrous and nonferrous metals can be oxy-acetylene welded. Used in pipe installation. In repairs (for example failed cast iron parts) Used in surfacing

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN

OXY-ACETYLENE WELDING
JOINT DESIGN
Flanged-edge welding Square-butt weld Vee-butt weld

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN

OXY-ACETYLENE WELDING
WELD PROBLEMS
Surface oxides Incomplete fusion Inclusions in the weld Weakening (reduction in strength)

WELDING METALLURGY & TECHNOLOGY

Dr. Caner BATIGN