Lab Session: 03

Oxy-Acetylene Welding

1. Title:

To investigate the effects of varying flow of oxygen and acetylene on gas welded specimen

2. Problem Statement:

Oxy-Acetylene Welding (generally known as Gas welding) has been around for many years and it
can be useful in welding a wide range of materials so it is essential to understand the process
properly. It is required to study different parameters involved, SOPs for the utilization of the
equipment and possible hazards encountered while operating the equipment.

3. Objective:

To understand the working principle and basic operating parameters of Oxy-Acetylene Welding

4. Theory:

4.1. Introduction:
Oxy-Acetylene welding, oxy-fuel welding, oxy welding, oxy-fuel cutting or gas welding are
processes that use fuel gases and oxygen to weld and cut metals, respectively. Pure oxygen, instead
of air, is used to increase the flame temperature to allow localized melting of the work piece
material (e.g. steel) in a room environment.

Figure 1: Oxy-Acetylene Welding (OAW) Station

4.2. Working Principal:
Gas welding is the process in which a gas flame is used to raise the temperature of the metals to
be joined. The metals are heated up to melting. The metal flows and on cooling it solidifies. A
filler metal may be added to the flowing molten metal to fill up cavity made during the end
preparation.

Figure 2: Working of Oxy-Acetylene Welding

4.3. Equipment:
Details of Gas welding equipment are as under:

4.3.1. Oxygen Cylinder:

Cylinder is made up of steel in capacity range 2.25 to 6.3 m3. The cylinders are filled with oxygen
at about 150 kg/cm2 at 21°C. A safety valve is also provided on it. The cylinder can be opened or
closed by a wheel which operates a valve. A protector cap is provided on the top of a cylinder to
safeguard the valve.

Figure 3: Oxygen Cylinder

4.3.2. Acetylene Cylinder:

Acetylene cylinders are also made up of steel. Gas is filled at a pressure of 18-20 kg/cm2. The
capacity of the cylinder is about 10m3. Regulator valve and safety valve are mounted on cylinder.
Safety plugs are also provided on the bottom of the cylinder. When filled into the cylinder, the
acetylene is dissolved in acetone.

Figure 4: Acetylene Cylinder

4.3.3. Regulator:

Regulator is used to control the flow of gases from high pressure cylinder. A simple type of
regulator is shown as below.

Figure 5: Regulator
4.3.4. Torch:

The torch is the part that the welder holds and manipulates to make the weld. It has a connection
and valve for the fuel gas and a connection, valve for the oxygen and handle for the welder to
grasp. Torch has a mixing chamber (set at an angle) where the fuel gas and oxygen mix, with a tip
where the flame forms
There are two types of torches:
(a) Low pressure or injector torches
(b) Medium pressure or equal pressure torches

Figure 6: Torch

(a) Low Pressure or Injector Torch: These torches are designed to use acetylene at low
pressure. The pressure is kept very low up to 0.7 kg/cm2. But the oxygen pressure is very high.
(b) Medium Pressure or Equal Pressure Torch: In this type of torch the acetylene is taken
at a pressure equal to 1 kg/cm2, the oxygen is always supplied at high pressure. Both types of
torches are provided with two needle valves. One regulates the flow of oxygen and the second
valve controls the flow of acetylene. A mixing chamber is provided to mix the gases.

4.3.5. Torch Tips:

For different types of jobs, different tips are used. The size of the tip is specified by the outlet hole
diameter. More than one hole is also provided in tips. The tip is screwed or fitted on the front end
of the torch.
 Figure 7: Torch Tips

4.3.6. Hoses and Connections:

A hose is a flexible hollow tube designed to carry fluids from one location to another. Hoses are
also sometimes called pipes (the word pipe usually refers to a rigid tube, whereas a hose is usually
a flexible one), or more generally tubing. The shape of a hose is usually cylindrical (having a
circular cross section). The equipment typically requires special nonporous hoses. For the
identification, hoses are color coded; (Green: oxygen, Red or Black: fuel gas) and connections
(Oxygen: right hand, Acetylene: left hand). Hoses should be protected from hot metal and physical
damage.

Figure 8: Hoses and Connections

4.4. Startup Procedure:

 Verify that equipment visually appears safe i.e.: Hose condition, visibility of gauges
 Clean torch orifices with a “tip cleaners” (a small wire gauge file set used to clean slag and
dirt form the torch tip)
 Crack (or open) cylinder valves slightly allowing pressure to enter the regulators slowly
 Opening the cylinder valve quickly will “Slam” (smash) the regulator and will cause
failure.
  Check for leaks using by listening for “Hissing” or by using a soapy “Bubble” solution
 Adjust the regulators to the correct operating pressure
 Slightly open and close the Oxygen and Acetylene valves at the torch head to purge any
atmosphere from the system.

4.5. Startup Procedure:

 Close cylinder valves
 Open torch valves
 Close torch valves
 Release tension on regulator adjusting screw.
 Roll up hoses and place torch in a safe position

4.6. Safety Precautions:

The following safety precautions must be observed while working on oxy-acetylene welding setup:
 Always handle the gas cylinders with care.
 The adjusting screw on the regulator must be fully released before opening a cylinder valve.
 Never use matchsticks for lighting a torch.
 Never lubricate the regulator valve with oil or grease, it may cause explosion.
 Always use goggles while working.
 Proper ventilation must be provided in the shop.
 Acetylene cylinders should be stored in up-right position.
 Do not open acetylene cylinders near sparks or fire.
 Never remove torch tips with pliers.
 The cylinder should be leak proof.
 Always use protective caps over the valves.
 Keep in mind the location of the fire extinguishers.

4.7. Welding Parameters:

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5. Defects:

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6. To Do Assignment:

Observe and study the oxy-acetylene welding process and complete the lab report as per the
study questions given below.
a. What are the types of gas flames produced in the process?
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 b. What are the types of gas welding techniques used to weld the specimen?

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c. What are the advantages and disadvantages of this process?

Advantages:
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Disadvantages:
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