GAS

WELDING
2022
Presented By:
Seif Wagdy (Team Leader) 19P8234
Mohamed Amr 19P3989
Ahmed Rafaat 19P4258
Kirollos Naguib 19P3989
Mina Tawfik 19P9641
Sandy Zakria 19P9258
Moemen Youssef 18P8394

Supervised By:

Dr. Ramadan El-Gamasy

Eng. Bassem Tarek

Contents
1. Introduction ......................................................................................3

1.1 Fusion welding: .........................................................................3

1.2 Gas welding: .............................................................................3

2.0 Oxyfuel: ..........................................................................................3

2.1 introduction: ..............................................................................3

2.2 Type of flames: .........................................................................4

• Carburizing Flame:....................................................................4

• Neutral Flame: ..........................................................................5

• Oxidizing Flame: .......................................................................5

3.0 Flux: ...............................................................................................5

3.1 Why we use flux: .......................................................................5

3.2 How it protects the weld pool: ...................................................5

3.3 Material used: ...........................................................................5

4.0 Techniques of welding: ...................................................................6

4.1 Leftwards or forehand: ..............................................................6

4.2 Rightwards or Backhand: ..........................................................6

5.0 Advantages: ...................................................................................6

6.0 Disadvantages: ...............................................................................6

7.0 Application: .....................................................................................7

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List of Figures

Figure 1 Gas Welding .............................................................................4

Figure 2 Carburizing Flame.....................................................................4
Figure 3 Neutral Flame ...........................................................................5
Figure 4 Oxidizing Flame ........................................................................5
Figure 5 Leftward Welding ......................................................................6
Figure 6 Rightward Welding ....................................................................6

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 1. Introduction
1.1 Fusion welding:
Fusion welding is a type of welding that depends on melting to join metals
of similar properties. Due to the high-temperature phase transitions
inherent to these processes, a heat-affected zone is created in the
material. Moreover, It is the welding in the liquid state with no pressure,
therefore, the union of the metals is by molten metal bridging. Moreover,
the source of heat is by chemical reaction, electric resistance, electric arc,
and power beams.

Fusion welding is used in the manufacture of many everyday items

including airplanes, cars, and structures. A large community uses both arc
and flame contact welding to create artwork. Fusion welding has many
types, such as: spot, seam and projection welding. Oxyfuel gas welding,
and Thermit welding. GMAW, MMAW, SAW, and GTAW. Laser and
electron beam.

1.2 Gas welding:

Gas welding is a welding process that heat metal until it become molten
and joins or fuse the metals by heating them with a flame caused by a
chemical reaction and combustion of fuel gas and oxygen.

We can use this method with filler or without filler, also it can be used
with pressure or without using pressure. Moreover, it can braze dissimilar
metals.

2.0 Oxyfuel:
2.1 introduction:
It uses oxyfuel flame which formed by combustion of the acetylene fuel
with the oxygen gas in the weld torch so that it will be a chemical reaction
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heat source. We use this method as it has a very high flame temperature
up to 3500 degree Celsius.

Figure 1 Gas Welding

2.2 Type of flames:

Flame formed by burning a mix of acetylene and oxygen. Furthermore,
fusion of metal is achieved by passing the inner cone of the flame over
the metal. In- addition, Oxyacetylene can also be used for cutting metals.

• Carburizing Flame:
Oxygen is turned on, flame immediately changes
into a long white inner area (Feather) surrounded by
a transparent blue envelope is called Carburizing
flame.

The excess amount of acetylene is used, giving a

reducing flame. The combustion of acetylene is
incomplete (greenish) between the inner cone and
the outer envelope. Good for welding aluminium Figure 2 Carburizing Flame

alloys, high carbon steels.

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 • Neutral Flame:
Addition of little more oxygen give a bright whitish
cone surrounded by the transparent blue envelope.
Also, It has a balance of fuel gas and oxygen. It is
used for welding steels, aluminium, copper and cast
iron

Acetylene and O2 are mixed in equal amounts and

Figure 3 Neutral Flame
burn at the tip of the welding torch. The inner cone gives
2/3 of heat whereas the outer envelope provides 1/3 of the energy.

• Oxidizing Flame:
If more oxygen is added, the cone becomes darker
and more pointed, while the envelope becomes shorter
and more fierce. it Has the highest flame temperature.
Also, it is used for welding brass and brazing
operation. Figure 4 Oxidizing Flame

3.0 Flux:
3.1 Why we use flux:
When metal is fused, oxygen from the atmosphere and the oxygen from
the torch combine with molten metal, so it may result in defective weld.
Because of that, we may use flux to deoxidize and cleanse the weld metal.

3.2 How it protects the weld pool:

The flux is melted then it is solidified so as a result, it forms a slag skin
on the weld metal, so it removes the oxides.

3.3 Material used:

• Potassium
• Lithium

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 • Sodium
• Borax

It also can be a paste, powder, liquid, gas, and solid coating.

4.0 Techniques of welding:

4.1 Leftwards or forehand:
Used for welding joints like butt welds,
lap joints, and fillet joints. Also, it used for
metal which have thickness up to 5mm.
and the angle of torch is high (60 to 70
degrees). Figure 5 Leftward Welding

4.2 Rightwards or Backhand:

Used for plates which have thickness
over 5mm as it has low angle (40 to 50
degrees) so it can preheat metal
before welding. Also, it used to weld
flat and horizontal and vertical
Figure 6 Rightward Welding
positions of the workpiece.

5.0 Advantages:
• Simple equipment
• Portable
• Inexpensive
• Easy for maintenance and repair

6.0 Disadvantages:
• Limited power density
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 • Very low welding speed
• High total heat input per unit length
• Large heat affected zone
• Severe distortion
• Not recommended for welding reactive metals such as titanium and
zirconium.

7.0 Application:
Oxy-acetylene flame is used for welding metals, having high melting
temperature such as mild steel, high carbon steel etc. On the other hand,
Oxy-hydrogen flame is used for welding metals having low melting
temperature such as aluminium, lead, magnesium.