1.

Gas Welding

1. Gas Welding

Although the oxy-acetylene process has been introduced long time ago it is still applied for its flexibility and mobility. Equipment for oxyacetylene welding consists of just a few elements, the energy necessary for welding can be transported in cylinders, Figure 1.1.
density in normal state [kg/m3]

3 4 5 8

7 1
2 9

ignition temperature [OC] 600 400 200 0

645

645
oxygen propane
natural gas

air

1 2 3 4 5 6 7 8 9

oxygen cylinder with pressure reducer acetylene cylinder with pressure reducer oxygen hose acetylene hose welding torch welding rod workpiece welding nozzle welding flame
ISF 2002

3200 2850 2770 0

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flame temperature with O2 flame efficiency with O2 flame velocity with O2 43 1350
10.3 8.5 370 330

acetylene

acetylene

300

490 335

510

propane

KW k

/cm2

cm

/s
ISF 2002

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Equipment Components for Gas Welding

Properties of Fuel Gas in Combination with Oxygen

Figure 1.1

Figure 1.2

Process energy is obtained from the exothermal chemical reaction between oxygen and a combustible gas, Figure 1.2. Suitable combustible gases are C2H2, lighting gas, H2, C3H8 and natural gas; here C3H8 has the highest calorific value. The highest flame intensity from point of view of calorific value and flame propagation speed is, however, obtained with C2H2.

natural gas

natural gas

air

2.5 2.0 1.5 1.0 0.5 0

2.0 1.29 1.17

acetylene

propane

1.43
oxygen

0.9

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1. Gas Welding

8 C2H2 is produced in acetylene gas genera-

loading funnel

tors by the exothermal transformation of calmaterial lock

cium carbide with water, Figure 1.3. Carbide is obtained from the reaction of lime and carbon in the arc furnace.

gas exit feed wheel

C2H2 tends to decompose already at a pressure of 0.2 MPa. Nonetheless, commercial quantities can be stored when C2H2 is dis-

grille sludge

solved in acetone (1 l of acetone dissolves approx. 24 l of C2H2 at 0.1 MPa), Figure 1.4.

to sludge pit
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Acetylene Generator

Figure 1.3

Acetone disintegrates at a pressure of more than 1.8 MPa, i.e., with a filling pressure of 1.5 MPa the storage of 6m of C2H2 is possible in a standard cylinder (40 l). For gas exchange (storage and drawing of quantities up to 700 l/h) a larger surface is necessary, therefore the gas cylinders are filled with a porous mass (diatomite). Gas consumption during welding can be observed from the weight reduction of the gas cylinder.

acetone

acetylene

porous mass

acetylene cylinder
acetone quantity : acetylene quantity : cylinder pressure : ~13 l 6000 l 15 bar

filling quantity : up to 700 l/h

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ISF 2002

Storage of Acetylene

Figure 1.4
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1. Gas Welding

9 Oxygen is produced by
gaseous cooling nitrogen cylinder

fractional distillation of liquid air and stored in cylinders with a filling presbundle

air

sure of up to 20 MPa, Figure 1.5. For higher oxygen consumption, storage in a liquid state and cold gasification is more profitable.

oxygen

liquid air

oxygen

pipeline liquid

tank car nitrogen vaporized cleaning

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compressor

separation

supply
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Principle of Oxygen Extraction

Figure 1.5

The standard cylinder (40 l) contains, at a filling pressure of 15 MPa, 6m of O2 (pressureless state), Figure 1.6. Moreover, cylinders with contents of 10 or 20 l (15 MPa) as well as 50 l at 20 MPa are common. Gas consumption can be calculated from the pressure difference by means of the general gas equation.
manometer

50 l oxygen cylinder
protective cap cylinder valve take-off connection

gaseous

N
p = cylinder pressure : 200 bar V = volume of cylinder : 50 l Q = volume of oxygen : 10 000 l content control Q=pV foot ring

safety valve

liquid
vaporizer

filling connection still liquid

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user gaseous

Storage of Oxygen

Figure 1.6

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1. Gas Welding

10

In order to prevent mistakes, the gas cylinders are colour-coded. Figure 1.7 shows a survey of the present colour code and the future colour code which is in accordance with DIN EN 1089.
old condition
blue

DIN EN 1089
white blue (grey)

old condition
grey

DIN EN 1089
brown grey

The cylinder valves also of

are

different designs. right-hand are

Oxygen cylinder connections show a cylinder thread union nut. Acetylene

oxygen techn.
yellow brown

helium
red red

acetylene
grey dark green grey

hydrogen
grey vivid green grey

valves

equipped with screw clamp retentions. Cylinder valves for other combustible gases have a left-hand thread-connection with a circumferential groove.

argon
darkgreen black darkgreen

argon-carbon-dioxide mixture
grey grey

nitrogen
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carbon-dioxide
ISF 2006

Gas Cylinder-Identification according to DIN EN 1089

Figure 1.7

cylinder pressure

working pressure

Pressure

regulators

re-

duce the cylinder pressure to the requested working pressure, Figures 1.8 and 1.9.

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ISF 2002

Single Pressure Reducing Valve during Gas Discharge Operation

Figure 1.8

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1. Gas Welding

11

At a low cylinder pressure (e.g. acetylene cylinder) and low pressure fluctuations, singlestage regulators
discharge pressure locking pressure

are applied; at higher cylinder pressures normally two-stage pressure regulators are used. The requested pressure is set by the adjusting screw. If the pressure increases on the low pressure side, the throttle valve closes the

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ISF 2002

increased

pressure

onto

Single Pressure Reducing Valve, Shut Down

the membrane.

Figure 1.9 The injector-type torch consists of a body with valves and welding chamber with welding nozzle, Figure 1.10. By the selection of suitable welding chambers, the flame intensity can be adjusted for welding different plate thicknesses. The special form of the mixing chamber guarantees highest possible safety against flashback, Figure 1.11. The high outlet speed of the escaping O2 generates a negative pressure in the acetylene gas line, in consequence C2H2 is sucked and drawn-in. C2H2 is therefore available with a very low pressure of 0.02 up to 0.05 MPa with O2 0.3 MPa). -compared (0.2 up to Figure 1.10
welding torch head
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welding torch injector or blowpipe

coupling nut mixer nozzle oxygen valve hose connection for oxygen A6x1/4" right

mixer tube

injector pressure nozzle suction nozzle welding nozzle fuel gas valve

hose connection for fuel gas A9 x R3/8 left

torch body
ISF 2002

Welding Torch

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1. Gas Welding

12

A neutral flame adjustment allows the differentiation of three zones of a chemical reaction, Figure 1.12: 0. dark core: 1. brightly shining centre cone: 2. welding zone: 3. outer flame: escaping gas mixture acetylene decomposition C2H2 -> 2C+H2 1st stage of combustion 2C + H2 + O2 (cylinder) -> 2CO + H2 2nd stage of combustion 4CO + 2H2 + 3O2 (air) -> 4CO2 + 2H2O complete reaction: 2C2H2 + 5O2 -> 4CO2 + 2H2O

acetylene oxygen acetylene

welding torch head injector nozzle coupling nut

pressure nozzle

torch body

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ISF 2002

Injector-Area of Torch

Figure 1.11

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13

welding flame combustion

welding nozzle centre cone welding zone 2-5 outer flame
excess of acetylene

welding flame ratio of mixture

normal (neutral) excess of oxygen

3200C

2500C

1800C

1100C

effects in welding of steel sparking

400C

consequences: carburizing hardening

ISF 2002
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foaming spattering reducing oxidizing

ISF 2002

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Temperature Distribution in the Welding Flame

Effects of the Welding Flame Depending on the Ratio of Mixture

Figure 1.12
welding flame
balanced (neutral) flame nozzle size: for plate thickness of 2-4 mm discharging velocity and weld heat-input rate: low 2

Figure 1.13

By changing the mixture ratio of the volumes O2:C2H2 the weld pool can greatly be influenced, Figure 1.13. At a neutral flame adjustment the mixture ratio is O2:C2H2 = 1:1. By reason of the higher flame temperature, an excess oxygen flame might allow faster welding of steel, however, there is the risk of oxidizing (flame cutting). Area of application: brass The excess acetylene causes the carburising of steel materials. Area of application: cast iron

soft flame
discharging velocity and weld heat-input rate: middle 3

moderate flame
discharging velocity and weld head-input rate: high 4

hard flame
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ISF 2002

Effects of the Welding Flame Depending on the Discharge Velocity

Figure 1.14

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By changing the gas mixture outlet speed the flame can be adjusted to the heat requirements of the welding job, for example when welding plates (thickness: 2 to 4 mm) with the welding chamber size 3: 2 to 4 mm, Figure 1.14. The gas mixture outlet speed is 100 to 130 m/s when using a medium or normal flame, applied to at, for example, a 3 mm plate. Using a soft flame, the gas outlet speed is lower (80 to 100 m/s) for the 2 mm plate, with a hard flame it is higher (130 to 160 m/s) for the 4 mm plate.

Depending on the plate thickness are the working methods leftward welding and rightward welding applied, Figure 1.15. A decisive factor for the designation of the working method is the sequence of flame and welding rod as well as the manipulation of flame and welding rod. The welding direction itself is of no importance. In leftward welding the flame is pointed at the open gap and wets the molten pool; the heat input to the molten pool can be well controlled by a slight movement of the torch (s 3 mm).
Leftward welding is applied to a plate thickness of up to 3 mm. The weld-rod dips into the molten pool from time to time, but remains calm otherwise. The torch swings a little. Advantages: easy to handle on thin plates

plate thickness range s [mm] from to

1,5

gap preparations
~ s+1 ~

denotation

symbol

r=

flange weld

welding-rod

flame

welding bead

1,0 1,0 4,0 plain butt weld

Rightward welding ist applied to a plate thickness of 3mm upwards. The wire circles, the torch remains calm. Advantages: - the molten pool and the weld keyhole are easy to observe - good root fusion - the bath and the melting weld-rod are permanently protected from the air - narrow welding seam - low gas consumption

3,0

12,0
1-2

V - weld

1,0

8,0

1-2

corner weld

1,0

8,0

lap seam

1,0
weld-rod
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8,0

fillet weld

flame
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ISF 2002

Flame Welding

Gap Shapes for Gas Welding

Figure 1.15

Figure 1.16

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1. Gas Welding

15 In rightward welding the flame is directed

PA
butt-welded seams in gravity position gravity fillet welds

onto the molten pool; a weld keyhole is formed (s 3 mm). Flanged welds and plain butt welds can be applied to a plate thickness of approx. 1.5 mm without filler material, but this does not apply to any other plate thickness and weld shape, Figure 1.16.

PB
s f

horizontal fillet welds vertical fillet and butt welds

PF PG PC

vertical-upwelding position vertical-down position horizontal on vertical wall

By the specific heat input of the different

PE
overhead position

welding methods all welding positions can be carried out using the oxyacetylene welding method, Figures 1.17 and 1.18

PD
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horizontal overhead position

ISF 2002

When working in tanks and confined spaces, the welder (and all other persons present!) have to be protected against the

Welding Positions I

Figure 1.17 welding heat, the gases produced during welding and lack of oxygen ((1.5 % (vol.) O2 per 2 % (vol.) C2H2 are taken out from the ambient atmosphere)), Figure 1.19. The addition of pure oxygen is unsuitable (explosion hazard!). A special type of autogene method is flamestraightening, where specific locally applied flame heating allows for shape correction of workpieces, Figure 1.20. Much experience is needed to carry out flame straightening processes. The basic principle of flame straightening de-

PA PB PF

PC

PG PD PE

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ISF 2002

pends on locally applied heating in connection with prevention of expansion. This procFigure 1.18
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Welding Positions II

1. Gas Welding

16

ess causes the appearance of a heated zone. During cooling, shrinking forces are generated in the heated zone and lead to the desired shape correction.

Safety in welding and cutting inside of tanks and narrow rooms

Flame straightening

welded parts

Hazards through gas, fumes, explosive mixtures, electric current protective measures / safety precautions 1. requirement for a permission to enter 2. extraction unit, ventilation 3. second person for safety reasons 4. illumination and electric machines: max 42volt 5. after welding: Removing the equipment from the tank

first warm up both lateral plates, then belt

butt weld 3 to 5 heat sources close to the weld-seam

double fillet weld 1,3 or 5 heat sources

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ISF 2002

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ISF 2002

Gas Welding in Tanks and Narrow Rooms

Flame Straightening

Figure 1.19

Figure 1.20

2005