MEC 218 Federal Polytechnic Nasarawa

Chapter 2: Gas Welding

2.0 Learning Outcomes
1.) Learn the principles of Gas Welding
2.) Learn how to use the different gas welding flames

2.1 Gas Welding Overview

2.1.1 Basic Definitions
Fusion welding: A thermal joining process in which the edges of the parent metal to be joined are melted and caused to
fuse together, with or without the use of a filler material. The two basic types of fusion welding are Gas welding and Arc
welding. Fusion welding methods are also used for cutting.

Filler material: A metal that is heated during welding to liquefy and fill the gaps in weld joints.

2.1.2 Principle of Oxy-acetylene Welding

Oxy-acetylene welding uses the combustion of the two gases; oxygen and acetylene, to create a source of intense heat,
providing a flame temperature of around 3000/3200 °C. This heat is sufficient to melt the surface of the metals being
joined, which run together and fuse to produce the weld. Additional material in the form of a filler rod may sometimes be
required.

Figure 1: Gas Welding Cylinders

The gases are supplied at a high pressure in steel cylinders which are made to rigid specifications. Low-pressure systems
are also available. Oxygen is supplied in cylinders painted black and provided with a right-hand threaded valve. Acetylene
is supplied in cylinders painted maroon and provided with a left-hand threaded valve. The use of opposite-hand threads
prevents incorrect connections being made. For ease of recognition, all left-hand nuts on acetylene fittings have grooved
corners.

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2.1.3 Fuel Sources

Oxy-Acetylene: Acetylene is the most commonly used fuel source for welding. Acetylene
(ethyne C2H2) is highly unstable and may explode when compressed above 1700 kPa.
Acetylene is therefore mixed with acetone when packed into cylinders. The acetylene
cylinder is also packed with a porous material (e.g. Styrofoam or fibre) which absorbs the
gas mixture and allows it to remain in liquid form.

Acetylene is commonly produced in a refinery and gas tanks may be refilled. However, in
Nigeria and other low-income countries it is commonly produced from a tank reaction of
calcium carbide (CaC2) and water.

CaC2 + 2H20 → C2H2 + Ca(OH) 2.

This reaction leaves behind a carbonate slurry called hydrated lime. Calcium carbide is a
white solid and is much easier to handle and transport. The acetylene is produced on-site
in a tank similar to the one shown in figure 2. Figure 2: Calcium Carbide Welding Tank

Oxy-gasoline: A mixture of oxygen and petrol. It can be used in low pressure systems. Petrol is widely available and
therefore relatively cheap. It is mostly used for cutting.

Oxy-Hydrogen: Can be used at a higher pressure than acetylene. It is used for underwater cutting and welding. In
underwater welding the hydrogen may be created from the electrolysis of water.

Butane/Propane: Butane and propane may be used individually or as a mix in gas cutting. Propane is cheaper, easier to
transport and produces a cleaner cut than acetylene.

2.2 Gas Welding (Safety) Considerations

When welding using a gas or mixture of gasses, several factors will affect the flame produced, procedure (especially
safety) and choice of equipment. Some of these factors are presented in this section (2.2).

Figure 3: Model of Oxy-Acetylene Supply System

Pressure regulators: Each regulator is fitted with two pressure gauges: one pressure gauge indicates the pressure of the
gas in the cylinder and the other pressure gauge indicates the reduced pressure at the outlet being fed to the welding
torch. Dirt is prevented from entering the regulator by momentarily opening the valve by a small amount before fitting
onto a cylinder (see figure 3).

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Discharge rate: This is the rate at which gases are used up. If the discharge rate of oxygen is too high, freezing may occur
due to a sharp drop in pressure. If the discharge rate of acetylene is too high, too much acetone may be sucked up, which
is corrosive to hoses and welding torches.

Welding hoses: These hoses are specially manufactured for this purpose and no other sort of hose should be used. The
rubber compound lining is chemically resistant to the normal welding gases. It is reinforced with a layer of canvas or
wrapped cotton to resist the pressure of the gases in the hose. There is also a tough rubber outer casing that is abrasion
resistant. Welding hoses are coloured black for oxygen and red for acetylene. Safety procedure involves not dropping
weights on hoses, rolling a trolley over them and avoiding contact with the flame.

Welding Torches: The hose connections on the torch body are threaded left or right so that only the correct hose can be
attached and there can be no chance of incorrect connection. There are two control valves so that the operator can set
the flame to suit the job in hand or turn the supply off completely.

Welding Nozzles: A welding nozzle (tip) is situated at the end of the welding torch neck where the gases emerge prior to
ignition and combustion (see figure 3). A well-designed nozzle enables the operator to guide the flame and direct it with
ease and efficiency. Nozzles are made from copper or copper alloy since these metals have a high thermal conductivity
and this property reduces the possibility of the nozzle overheating and becoming damaged by the heat radiating from the
weld zone.

2.3 Types of Gas Flames

During oxy-acetylene welding, it is the flame which does the work and is therefore very important. The welding equipment
already described merely serves to maintain and control the flame. It is the operator who sets the controls to produce a
flame of the proper size, shape and condition to operate with maximum efficiency to suit the particular conditions.

The ratio of acetylene to oxygen used in producing the welding flame is to be finely controlled in welding.

The general process of starting the welding flame is given

below:

1.) Open the acetylene control valve on the torch and light the
gas with a suitable spark lighter.
2.) Adjust the flame so that it burns without smoke or sooty
deposit.
3.) Open the oxygen control valve on the torch and adjust to
give a well-defined inner cone as described in a neutral
flame (described below).
4.) When welding is finished, extinguish the flame by first
closing the acetylene control valve on the torch followed by
closing the oxygen control valve on the torch.

By adjusting the amounts of oxygen and acetylene it is possible

to achieve three types of flame condition:
Figure 4: Gas Welding Flame Types

Neutral flame: The neutral flame as shown in Fig. 4(a), consists of approximately equal amounts of oxygen and acetylene
being burned. Having adjusted the acetylene as described, the oxygen is adjusted to give a clearly defined light-blue inner
cone, the length of which is two to three times its width. This indicates equal amounts of the gases are being used,

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combustion is complete and the flame is ‘neutral’. This flame is the one most extensively used, having the advantage that
once the metal has fused, it is chemically the same as before welding. It is used for general welding.

Carburizing flame: The carburizing (reducing) flame, Fig. 4(b), has an excess of acetylene being burned. Start with a neutral
flame and slightly increase the quantity of acetylene. The inner cone will become surrounded by a white feathery plume
which varies in length according to the amount of excess acetylene.

This flame is used when hardfacing – a process in which a layer of hard metal is deposited on the surface of a soft metal
to give localised resistance to wear. This type of flame should be avoided when welding steels. It is also used when ‘flame
brazing’ aluminium and its alloys.

Oxidising flame: The oxidising flame, Fig. 4(c), has an excess of oxygen being burned. Start with a neutral flame and slightly
increase the quantity of oxygen (or reduce the acetylene). The inner core will take on a sharper pointed shape and the
flame is fiercer with a slight hissing sound.

The oxidizing flame is undesirable in most cases as it oxidizes the molten metal in the weld pool, causing heavy scaling.
The oxidizing flame give the highest temperature providing the oxygen: acetylene ratio does not exceed 1.5:1.

This type of flame is used when welding brasses and should be avoided when welding steels. Melting brass with a neutral
flame causes violent evolution of zinc fumes. This is due to the zinc content of the alloy boiling and being given off as a
gas. Zinc lost in this manner results in a porous and weak welded joint

2.4 Assignment
1.) List seven (7) safety Do’s and Don’ts in Gas-Welding.

2.) By the aid of a table list three (3) differences between the three (3) flame types.

2.5 Bibliography
[1] Fabrication and welding Engineering, Roger Timings. 2008. [2] Auto.edu [accessed June, 2021].

[3] Weld guru.com [accessed June, 2021]

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