GAS WELDING

Introduction
Oxy-acetylene flame is commonly used for gas welding. Acetylene is widely used as the
combustible gas because of its high flame temperature when mixed with oxygen. The temperature,
which ranges from approximately 5,700° to 6,300°F, is so far above the melting point of all
commercial metals that it provides a means for the rapid, localized melting essential in welding. It
consists of the supply of oxygen and acetylene under pressure in cylinders, pressure
regulators, a torch, hoses and accessories like goggles and lighter.
The oxygen and acetylene cylinder are connected to the torch through pressure regulator
and hoses. The regulator consists of two pressure gauges, one for indicating the pressure
within the cylinder and other shows the pressure of the gas fed into the torch, which may
be regulated.
The torch mixes the two gases and the flame may be controlled by adjusting the
oxygen and acetylene supply. A coalescence or bond is produced by heating with a gas flame or
flames obtained from the combustion of acetylene with oxygen, with or without the application of
pressure, and with or without the use of filler metal.
A welding torch is used to mix the gases in the proper proportions and to direct the flame
against the parts to be welded. The molten edges of the parts then literally flow together and, after
cooling, form one solid piece. Usually, it is necessary to add extra material to the joint. The correct
material in rod form is dipped in and fuses with the puddle of molten metal from the parent metal
parts.

Salient points about oxyacetylene welding

1. The heat is obtained by combustion of acetylene and oxygen. Here primary combustion occurring
in the inner zone gives:
C 2H2 + O2 →2CO + H2 + Heat
And the second reaction in the outer zone gives
2CO + H2 +1.5O2 → 2CO2 + H2 O + Heat
2. The maximum temperature at the tip of inner cone reaches up to 3000-3500°C. Therefore,
most gas welding is performed by keeping this inner zone tip just above the metal to be
welded so that maximum temperature is available for welding.
Basic Fuel Gas welder parts
Flame Types
1. A neutral flame is obtained when the ratio of is oxygen and acetylene is 1. Most gas welding
operations are carried out by this flame.
2. An oxidizing flame is obtained when this ratio is more than 1. This type of flame is not
suitable for welding of steels since excess oxygen present reacts with carbon in steel and is
generally used for welding of copper and its alloys.
3. When the ratio in mixture is less than 1, a carburizing flame is obtained. In this type of flame
acetylene decomposes into carbon and hydrogen and the flame temperature gets reduced.
Joining operations such as brazing and soldering which require lower temperature generally
use this flame.

Oxidising Flame

Carburizing Flame

Neutral Flame
Filler rods
1. Mild steel welding rods are usually cupper coated to prevent rusting.
2. Cast iron rods are square shaped. Brazing rods are made of brass or bronze.
3. Filler rod size increases as the metal thickness to be joined increases.
4. For oxy acetylene gas welding filler rods are not coated with flux.

Welding process
The following are the steps involved in a gas welding work:
1. Prepare the work pieces to be welded and place them in proper position on the welding table.
2. Wear goggles, gloves and apron.
3. Select proper size tip for the job and fix it to the torch.
4. Select the filler rod of recommended size.
5. Adjust the welding equipment and light the torch.
6. Adjust the torch for neutral flame.
7. Hold the torch; with the inner cone about 3mm away from the metal and tack- welds the
pieces at either end.
8. Starting from one end, weld along the edge with a zig- zag torch movement. Add the filler
metal to the joints as welding progresses.
In leftward welding, most of the heart is absorbed by filler material and hence it is preferred in
welding thin sheets up to 6mm thick. In rightward welding, most of the heart is absorbed by the
base metal and so it is preferred in welding thick sheets of 6 to 25 mm thick.

Flame Cutting
1. Metal is melted by the flame of the oxy-fuel gas torch and blown away to form a gap.
2. When ferrous metal is cut, actually burning of iron takes place according to one or more of
the following reactions.
Fe + O FeO +Q
3Fe + 2O2 Fe3O4+Q
4Fe + 3O2 2Fe2O3+Q
3. Because, these reactions cannot take place below 815°C. Oxy-fuel flame is first used to
raise the metal temperature where burning can be initiated. Then a stream of pure oxygen is
 added to the torch (or the oxygen content of the oxy-fuel mixture is increased) to oxidize
the iron.
4. The liquid iron and iron oxides are then expelled from the joint by the kinetic energy of the
oxygen gas stream.
5. Low rate of heat input, and need of preheating ahead of the cut, oxy-fuel produces a
relatively large heat affected zone and thus associated distortion zone.
6. The process is suitable when edge finish or tolerance is not critical.
7. Theoretically heat generated due to burning of Fe is sufficient to continue cutting, however
due to losses additional heat supply is needed.
8. If the work is already hot from the other processes, supply of oxygen through a small
diameter pipe is needed to continue cut. This is called Oxygen Lance Cutting. A work piece

temperature of 1200°C is needed to sustain the cutting.

Shutting- Off the Equipment

After completing gas-welding operation, the following procedure must be followed for shutting-
off the equipment:
1. First close the torch acetylene valve and the torch oxygen valve.
2. Close the acetylene cylinder valve first and then oxygen cylinder valve.
3. Drain the gas from the regulator and hose by opening the torch acetylene valve.
4. Drain the oxygen from the regulator and hose opening the torch oxygen valve.
5. Open the regulator screws on each regulator and remove the pressure from the diaphragms of
the regulators.
6. Hang- up the hose and torch.

Advantages of Gas Welding

1. It can be used for a wide variety manufacturing processes and repairs.
2. As the source of heater and filler metal are different, the welder can have control over filler
metal deposition rates.
Disadvantages of Gas welding
1. It is not economical to join heavy sections.
2. Flame temperature is less than the temperature of the arc welding.
3. Fluxes used, produce fumes that are irritating in nature.