ASSIGNMENT NO 5

OXY-FUEL GAS WELDING

Introduction:
Oxy fuel gas welding was firstly discovered by French engineers Charles Picard
and Edmond Ficher in 1903. It is a very common process used for permanent fasting of metals
and is also cheap hence it is used by the millions of people. It requires normal skill of worker
means it is not a very complex process.

Explanation:
In this process we use two gasses one is the oxygen and one is the fuel gas it
may be acetylene, propane, gasoline etc. this process works by the mixing up of fuel gas with the
oxygen which is mainly used in all purposes like it is compulsory to use oxygen in all process
and we can’t ignore its significance in oxy fuel welding process it enhances the flame and it
helps in better combustion of fuel gas to be used in the process mainly the commonly used
process nowadays by the local workers is oxyacetylene gas welding because of its significance
unlike electric arc welding it requires less skill for worker.

Types:
Oxy-fuel gas welding types are given below

 Oxy-acetylene welding
 Acetylene welding (AAW)
  Oxy Hydrogen welding (OHW)
 Pressure gas welding (PGW)
Oxy-acetylene welding
Oxy acetylene welding is a very common welding process which
involves the mixing up of oxygen gas with acetylene gas for the welding process. The gases are
kept in the different cylinders one is used for oxygen it is generally black in color and the color
used for the acetylene gas is generally maroon in color. The gasses mix-up in the mixing
chamber of the torch and the main function of oxygen here is the better combustion of fuel gas
which is generally acetylene in this process.

The most common fuel used in welding is acetylene, which has a two-stage reaction. The
primary chemical reaction involves the acetylene disassociating in the presence of oxygen to
produce heat, carbon monoxide, and hydrogen gas
 C2H2 + O2 → 2CO + H2.+ Heat

The acetylene gas produces three types of flame with the mixing up of oxygen these flames are
stated below

 Neutral flame
 Oxidizing flame
 Carburizing flame

Neutral flame
Neutral flame is composed of equal amount of the oxygen and acetylene gas
like it is 1:1 of acetylene and oxygen and is used for the welding of the metals given below

 Mild steel.
 Stainless steel.
 Cast Iron.
 Copper.

 Aluminum.

It has temperature at the inner cone tip is approximately 5850ºF (3232ºC),

while at the end of the outer sheath or envelope the temperature drops to approximately
2300ºF (1260ºC).
Carburizing flame
Carburizing flame is a flame which is composed of more acetylene and
less oxygen it contains 1:2 of oxygen and acetylene respectively this type of flame is used mainly
for the metals given below

 High carbon steel

 Non ferrous alloys
 Nickel
 Monel

It has a temperature of 550 F which is sufficiently used for the heating

purposes and welding of such metals or alloys which absorb less carbon

Oxidizing flame
Oxidizing flame is a type of flame which has the more percentage of oxygen
in the torch and it is mainly the composition of 2:1 of oxygen and acetylene respectively this
flame is mainly used for the metals given below

 Zinc
 Copper
  Manganese steel
 Cast iron
 Brass
 Bronze
It has mainly temperature of 6300F approximately and is often used for
cutting purposes. In case of steel the oxidizing flame may not be suitable as the deposited metal
will be porous, oxidized, and brittle. This flame will ruin most metals and should be avoided.

Equipment used:

The equipment used for this process is as follows .

 Cylinders
 Regulators
 Hose pipes
 Torch
 Control valves
Oxy-hydrogen welding:
Oxy-hydrogen Welding is a Gas Welding process using a
combustion mixture of Hydrogen (H2) and oxygen (O2) for producing gas welding flame.
Oxyacetylene flame has a temperature of about 4500°F (2500°C).

Process:
The equation for this type of welding is

 2H2 + O2 = 2H2O + heat

The process of welding with oxy-hydrogen is similar to other hot-flame

processes and the joints must be beveled in the same way to make them accessible for filling.
The work should be heated first, in order to prevent chilling of the filling material, and the melt
bar fused in to make the joint. In Germany this gas is used to heat plates and then they are
welded by hammering, as in blacksmith work, this operation being used to a large extent in
making large steel pipes. Iron, steel, copper, lead, zinc, and the other industrial metals can be
welded by this process; the cost is similar to that for work done by the oxy-acetylene process,
although somewhat higher for most operations. Each metal requires its own special method
of treatment and the operator will soon learn the best ways of handling each job, but this process
requires a skilled workman and the success or failure of the weld will depend largely on the man
who does it.
Process:
The use of oxygen and hydrogen as the gases for welding and cutting is older
than the oxy-acetylene process and dates back to before the production of oxygen by either
electrolysis or liquefaction of air. Oxygen was probably generated in those days from potassium
chlorate and manganese dioxide, or perhaps from potassium and sodium peroxides and water,*
and the hydrogen from hydrochloric acid and zinc. The oxy-hydrogen process was developed by
Newman who used detonating gas (pure oxygen and hydrogen mixed) at a pressure of about 3
atmospheres. This gas is still used to some extent in welding platinum, lead, and
precious metals but it is rapidly being superseded by apparatus designed to use the oxygen and
hydrogen from separate cylinders.
Gas pressure welding:
In this type of welding, the necessary heat is produced by the
combination of oxygen and acetylene gases. The rail ends to be welded are brought together and
heat is applied through a burner connected to oxygen and acetylene cylinders by means of
regulators and tubes. A temperature of about 1200 o C is achieved. At this temperature, the metal
of the rail ends melts, resulting in the fusion and welding together of the ends. The rails to be
welded are clamped at the wall by applying a pressure of 40 t pressure, heated to a temperature
of about 1200 o C to 1400 o C, and butted with an upset pressure of about 20 t. Then the joint is
again heated to a temperature of 850 o C and allowed to cool naturally. It has been seen that this
method of welding is cheaper as compared to flash butt welding. The quality of this welding
joint is also claimed to be quite good. There are both stationary and mobile units available for
gas pressure welding.