INTRODUCTION TO WELDING

• Welding is a process for joining two similar or dissimilar metals by

fusion.

• It joins different metals/alloys, with or without the application of

pressure and with or without the use of filler metal.

• The fusion of metal takes place by means of heat. The heat may be
generated either from combustion of gases, electric arc, electric
resistance or by chemical reaction.
During some type of welding processes, pressure may also be employed,
but this is not an essential requirement for all welding processes.

Welding provides a permanent joint but it normally affects the

metallurgy of the components.

It is therefore usually accompanied by post weld heat treatment for most
of the critical components.
The welding is widely used as a fabrication and repairing process in

industries.

Some of the typical applications of welding include the fabrication of

ships, pressure vessels, automobile bodies, off-shore platform, bridges,

welded pipes, sealing of nuclear fuel and explosives, etc.

• Most of the metals and alloys can be welded by one type of welding
process or the other.

• However, some are easier to weld than others. To compare this ease in
welding term ‘weldability’ is often used.

• The weldability may be defined as property of a metal which indicates

the ease with which it can be welded with other similar or dissimilar
metals.
• Weldability of a material depends upon various factors like the
metallurgical changes that occur due to welding, changes in hardness
in and around the weld, gas evolution and absorption, extent of
oxidation, and the effect on cracking tendency of the joint.

• Plain low carbon steel (C-0.12%) has the best weldability amongst
metals.

• Generally it is seen that the materials with high castability usually

have low weldability.
Terminological Elements Of Welding Process
• The terminological elements of welding process used with common
welding joints such as base metal, fusion zone, weld face, root face,
root opening toe and root .
The following are definitions of some of the welding terms that are
generally used.
Backing- It is the material support provided at the root side of a weld
to aid in the control of penetration.
Base metal -The metal to be joined or cut is termed as the base metal.
Bead or weld bead Bead- is the metal added during a single pass of
welding. The bead appears as a separate material from the
base metal.
Crater: In arc welding, a crater is the depression in the weld metal pool
at the point where the arc strikes the base metal plate.

Deposition rate :The rate at which the weld metal is deposited per unit
time is the deposition rate and is normally expressed as kg/h.

Fillet weld The metal fused into the corner of a joint made of two
pieces placed at approximately 90 degrees to each other, is termed fillet
weld.
Penetration - It is the depth up to which the weld metal combines with the

base metal as measured from the top surface of the joint.

Puddle - The portion of the weld joint that melted by the heat of welding is

called puddle.

Root - It is the point at which the two pieces to be joined by welding is

nearest.

.
• Tack weld- A small weld, generally used to temporarily hold the two

pieces together during actual welding, is the tack weld

• Toe of weld- It is the junction between the weld face and the base

metal.

• Weld face - It is the exposed surface of the weld,

Weld metal - The metal that is solidified in the joint is called weld

metal. It may be only base metal or a mixture of base metal and filler

metal.

Weld pass - A single movement of the welding torch or electrode along

the length of the joint which results in a bead is a weld pass.

 Types of welded joints
Different types of welding joints are classified as butt, lap, corner, tee
and edge joints.
 The choice of the type of joint depends on the weldment being made
and the sheet thickness.
 Welding Positions
There are four types of welding positions, which are given as:

1. Flat or down hand position

• The flat position or down hand position is one in which the welding is performed

from the upper side of the joint and the face of the weld is approximately

horizontal.

• This is the simplest and the most convenient position for welding.
• Using this technique, excellent welded joints at a fast speed with minimum risk of fatigue to

the welders can be obtained.

2. Horizontal Welding Position
• In horizontal position, the plane of the workpiece is vertical and the
deposited weld head is horizontal.

• The metal deposition rate in horizontal welding is next to that achieved

in flat or downhand welding position.

• This position of welding is most commonly used in welding vessels and

reservoirs
• A weld in the horizontal position occurs when the weld runs on a line

parallel with the horizon.

If the difference between welding on a flat surface and welding in the

horizontal position isn’t clear, think of the former like writing on a

desk and the latter like writing on a chalkboard.

• One key difference between welding on a flat surface and welding in
the horizontal position is that you need to maintain a shorter arc and
lower amperage (about 5 to 10 amps lower) when you’re welding in
the horizontal position.

• If you’re right-handed, weld left to right across your body just like
you’re reading. If you’re left-handed, weld in the opposite direction.

• Be certain to maintain the correct arc length across the surface of the
metal.
Keeping a nice tight arc helps keep the molten puddle from sagging
(and a sagging puddle won’t fill the top edge of the weld).

Using a narrow weaving motion and pausing at the top as you weld
reduces the chances that your weld sags.

If you come to the end of the joint and you still have some of your

electrode left over, don’t throw it away! You can always use it for more

Practice!!
Welding horizontal
3. Vertical Welding Position
In vertical position, the plane of the workpiece is vertical and the weld is
deposited upon a vertical surface.

It is difficult to produce satisfactory welds in this position due to the

effect of the force of gravity on the molten metal.

The welder must constantly control the metal so that it does not run or
drop from the weld.
• Vertical welding may be of two types viz., vertical-up and vertical-
down.

• Vertical-up welding is preferred when strength is the major

consideration.

• The vertical-down welding is used for a sealing operation and for

welding sheet metal.
Practicing vertical-up welding
Vertical-down stick welding

Electrode selection is important when you’re vertical-down stick

welding.

You need to account for the thickness of the metal you’re welding,

The technique for vertical-down stick welding starts with the angle of

your electrode.
1. To start the weld, tilt your electrode 65 degrees upward, starting at the top of
the joint you’re planning to weld.

Vertical-down stick welding is faster than vertical-up stick welding

because gravity is more on your side.
2. Strike your arc and keep it short.
3. Weld downward and be sure to form the bead fast enough to keep the
molten slag and metal from running ahead of the crater (the ending point of
the weld).

That helps to keep the weld nice and clean

Practicing vertical down stick welding.
 4. Overhead Welding Position
• The overhead position is probably even more difficult to weld than the
vertical position.

• Here the pull of gravity against the molten metal is much greater. The
force of the flame against the weld serves to counteract the pull of gravity.

• The welding is carried out from the underside. The electrode

is held with its welding end upward.
• It is a good practice to use very short arc and basic coated electrodes
for overhead welding.
Practicing overhead stick welding
Overhead welding can be hard work, and it requires a pretty awkward
stance. To help you maintain some level of comfort, placing the
electrode holder cable over your shoulder.

That lessens the weight you’re holding up with your arms, which
should allow you to weld for longer periods of time without resting.

When you’re welding overhead, check your clothes often to make

sure falling molten metal hasn’t stuck in any cracks or folds. It’s also a
good idea to wear a welder’s hat and heavy shoes.
 Advantages of Welding

1.Welding is more economical and is much faster process as compared

to other processes (riveting, bolting, casting etc.)

2. Welding, if properly controlled results permanent joints having

strength equal or sometimes more than base metal.
3. Large number of metals and alloys both similar and dissimilar can be
joined by welding.
4. General welding equipment is not very costly.
5. Portable welding equipments can be easily made available.

6. Welding permits considerable freedom in design.

7. Welding can join welding jobs through spots, as continuous pressure

tight seams, end-to-end and in a number of other configurations.

8. Welding can also be mechanized.

 Disadvantages of Welding

1 It results in residual stresses and distortion of the workpieces.

2. Welded joint needs stress relieving and heat treatment.

3. Welding gives out harmful radiations (light), fumes and spatter.

4. Jigs, and fixtures may also be needed to hold and position the parts to

be welded
5. Edges preparation of the welding jobs are required before welding

6. Skilled welder is required for production of good welding

7. Heat during welding produces metallurgical changes as the structure

of the welded joint is not same as that of the parent metal.

 Welding Electrodes
• An electrode is a piece of wire or a rod of a metal or alloy, with or
without coatings.
• An arc is set up between electrode and workpiece. Welding electrodes
are classified into following types:
(1) Consumable Electrodes
(a) Bare Electrodes
(b) Coated Electrodes
(2) Non-consumable Electrodes
(a) Carbon or Graphite Electrodes
(b) Tungsten Electrodes
Looking at electrode classifications

You can find dozens of different kinds of electrodes for many types of

stick welding.

Luckily, the American Welding Society uses number codes to convey the

different characteristics of each kind of stick welding electrode.

E6012 and E6013:

These electrodes offer a soft arc, and they produce a smooth bead with

thick slag covering the finished weld. Use them for thinner metals and

ill-fitting joints.
E6010 and E6011:
These options are versatile electrodes that you can use on dirty, rusty, and oily
metal without compromising the strength
of the finished weld.

You can use the E6011 either AC or DC polarity (the direction electricity flows),
but you can use the E6010 with direct current electrode positive polarity only.

The E6011 is an all-purpose electrode and produces very little slag on the
finished weld.
E7016 and E7018:

Both of these electrodes have iron powder in the flux, and that results
in very strong welds.

However, the weld puddle can be very hard to control for beginners
who try to use these electrodes.

Some stick welding electrodes become unusable when they’re

exposed to moisture in the air because they’re dried at high
temperatures in a low moisture environment when they’re
manufactured.
Some of the kinds that are most affected include 7016 electrodes,7018
electrodes, and all stainless steel electrodes.

If you leave these kinds of electrodes outside — even if they’re in

unopened cardboard containers — they pick up moisture from the
air, and their quality is compromised.

The worst part is that you can’t easily tell when an electrode has
absorbed moisture. You usually know only when your finished welds
turn out weak and porous.
• The best way to keep many of your electrodes completely dry is to

keep them in a heated electrode storage oven.

• Never put 6010 or 6011 electrodes in your electrode oven. They have

a water-based flux that will dry out and crack, making them unusable.
Electrode storage oven.
A layout of several electrodes
Characteristics of stick welding electrodes
A number of characteristics vary from one stick welding electrode to
another, so consider the following list when you’re choosing an
electrode for your stick weld:
1. Type of material:
You must match stick welding electrodes to the type of metal that
you’re going to weld — that is, cast-iron electrodes weld cast iron,
aluminum electrodes weld aluminum, and so on.
The five basic groups of electrode material are mild steel, high carbon
steel, cast iron, nonferrous (iron-free), and special alloy.
2.Strength:

The strength of a metal is measured in tensile strength. The

tensile strength of mild steel is about 40,000 pounds; high carbon or
alloyed steels can have a tensile strength of up to 160,000 pounds, which is
an extremely strong metal.

The welds you make when stick welding need to be stronger than the base
metal you’re working on, so be sure that the electrodes you select are
stronger than the base metals you’re working on.
3. Size:

Stick welding electrodes come in a wide range of sizes, including

1⁄16, 5⁄64, 3⁄32, 1⁄8, 3⁄16, 7⁄32, 1⁄4, and 5⁄16 inch. Most stick welding
is done with a 3⁄32- or 1⁄8-inch electrode.

The smaller electrodes are useful for stick welding with low amounts
of electric current, and when you’re welding in odd positions.

Believe it or not, larger electrodes are cheaper than smaller ones!

The rule for electrode sizes is that the electrode core wire should
never be larger than the thickness of the metal you’re planning to stick
weld.

4. Welding position:

You can find electrodes made for flat welding only, for both flat and
horizontal welding, or for all welding positions, so be sure your
electrode matches the position you plan to use.
5. Presence of iron powder:

 To increase the volume of molten metal that you deposit during a

weld, some electrodes have up to 60 percent iron powder mixed into

their flux (the outer coating that surrounds the electrode’s metal wire).

The heat generated during the welding process converts the iron

powder to steel, which ramps up the amount of metal that you deposit

into the welded joint.

The downside is that the presence of iron powder in an electrode can
make stick welding much harder to control when you’re welding in an
unusual or difficult position.

6. Soft arc designation:

Some electrodes are designed with what’s called a soft arc. These
electrodes are for thin metal and for filling gaps or pieces that don’t fit
well together.
Success of any stick welding project.

Five factors that can greatly influence the success of any stick welding

project.

1. Current:

The type of current or polarity you use is either AC or DC. If

you use the wrong current, the weld doesn’t deposit correctly.
2. Length of arc:

The arc of electricity that you maintain between your electrode and
the parent metal should be about the length of (and no longer than) the
diameter of your electrode’s core wire.

 A proper arc makes a continuous frying sound. Welding with a long

arc makes an uneven crackling sound, and sometimes the arc can go
out. It creates excessive weld spatter, and your weld bead is uneven
and wide.
3. Angle of electrode:

The angle created by your electrode and the parent metal should be no

more than 5 to 15 degrees in the direction you’re welding. If you don’t

get the angle right, your welding penetration won’t be correct.

4. Manipulation of the puddle:

The puddle of molten metal that you creat as you weld can have gas

pockets in it that compromise the strength of your weld.

5. Speed of travel:

The speed at which you move the electrode across the parent metal is
critical. If the travel speed is too slow, you end up with too large a
weld.

You waste your electrodes, and the excessive heat causes warping. If
you’re trying to rush and the travel speed is too fast, you end up with a
weld bead that’s far too narrow.
GAS WELDING PROCESS

• A fusion welding process which joins metals, using the heat of combustion

of an oxygen /air and fuel gas (i.e. acetylene, hydrogen propane or butane)

mixture is usually referred as ‘gas welding’.

• The intense heat (flame) thus produced melts and fuses together the edges

of the parts to be welded, generally with the addition of a filler metal.

The carbon monoxide (CO) and hydrogen produced in the first stage
further combine with the atmospheric oxygen and give rise to the outer
bluish flame.

Schematic of an oxy acetylene gas welding flame (neutral flame)

• The fuel gas generally employed is acetylene; however gases other
than acetylene can also be used though with lower flame temperature.

• Oxy-acetylene flame is the most versatile and hottest of all the flames
produced by the combination of oxygen and other fuel gases.

• Other gases such as Hydrogen, Propane, Butane, Natural gas etc., may
be used for some welding and brazing applications.
Characteristics of fuel gases
Gas welding operation
 Oxy-Acetylene Welding
• In this process, acetylene is mixed with oxygen in correct proportions
in the welding torch and ignited.
• The flame resulting at the tip of the torch is sufficiently hot to melt and
join the parent metal.
• The oxy-acetylene flame reaches a temperature of about 3300°C and
thus can melt most of the ferrous and non-ferrous metals in common
use.
• A filler metal rod or welding rod is generally added to the molten
metal pool to build up the seam slightly for greater strength.
 Types of Welding Flames
• In oxy-acetylene welding, flame is the most important means to
control the welding joint and the welding process.
• The correct type of flame is essential for the production of satisfactory
welds.
• The flame must be of the proper size, shape and condition in order to
operate with maximum efficiency.
• There are three basic types of oxy-acetylene flames.
1. Neutral welding flame (Acetylene and oxygen in equal
proportions).
2. Carburizing welding flame or reducing (excess of acetylene).
3. Oxidizing welding flame (excess of oxygen)
 Neutral Welding Flame
• A neutral flame results when approximately equal volumes of oxygen
and acetylene are mixed in the welding torch and burnt at the torch tip.
• The temperature of the neutral flame is of the order of about 5900°F
(3260°C).
• It has a clear, well defined inner cone, indicating that the
combustion is complete.
• The inner cone is light blue in color. It is surrounded by an outer flame
envelope, produced by the combination of oxygen in the air and
superheated carbon monoxide and hydrogen gases from the inner cone.
• This envelope is Usually a much darker blue than the inner cone.
• A neutral flame is named so because it affects no chemical change
on the molten metal and, therefore will not oxidize or carburize the
metal.
• The neutral flame is commonly used for the welding of mild steel,
stainless steel, cast Iron, copper, and aluminium.
NEUTRAL FLAME
The neutral flame is the exact point where the feather and the inner
cone come together.

In this flame, there is exactly enough oxygen present to provide total
combustion of the fuel gas.

Most welding and cutting operations use a neutral flame.

The neutral flame has a bright white primary flame and a colorless to
bluish secondary flame
 Carburizing or Reducing Welding Flame
• The carburizing or reducing flame has excess of acetylene and can be
recognized by acetylene feather, which exists between the inner cone
and the outer envelope.

• The outer flame envelope is longer than that of the neutral flame and is
usually much brighter in color.

• With iron and steel, carburizing flame produces very hard, brittle
substance known as iron carbide.
• A reducing flame may be distinguished from carburizing flame by the
fact that a carburizing flame contains more acetylene than a reducing
flame.

• A reducing flame has an approximate temperature of 2900 -3038°C.

• A carburizing-flame is used in the welding of lead and for carburizing

(surface hardening) purpose.

• A reducing flame, on the other hand, does not carburize the metal;
rather it ensures the absence of the oxidizing condition.
• It is used for welding with low alloy steel rods and for welding those
metals, (e.g., non-ferrous) that do not tend to absorb carbon. This
flame is very well used for welding high carbon steel.
Carburizing flame
The length of the flame feather is an indication of the excess acetylene
present.
Since unburned carbon present, goes into the weld metal pool, the
metal appears to boil.
 This excess carbon causes the steel to become extremely hard and
brittle.
 The carburising flame is not suggested for general use.
However, since this flame provides a strong reducing atmosphere in
the welding zone, it is useful for those materials which are readily
oxidised, for example, oxygen free copper alloys.
• It is also used for high carbon steels, cast irons and hard surfacing with

high speed steel and cemented carbides.

• Sometimes a reducing flame with only atmospheric oxygen supply is

used to deposit carbon on mould cavity faces to act as an insulator.

 Oxidising Welding flame
• The oxidizing flame has an excess of oxygen over the acetylene.
• An oxidizing flame can be recognized by the small cone, which is
shorter, much bluer in color and more pointed than that of the neutral
flame.
• The outer flame envelope is much shorter and tends to fan out at the
end.
• Such a flame makes a loud roaring sound. It is the hottest flame
(temperature as high as 6300°F) produced by any oxy-fuel gas source.
• But the excess oxygen especially at high temperatures tends to
combine with many metals to form hard, brittle, low strength oxides.

• Moreover, an excess of oxygen causes the weld bead and the

surrounding area to have a scummy or dirty appearance.

• For these reasons, an oxidizing flame is of limited use in welding. It is

not used in the welding of steel. A slightly oxidizing flame is helpful
when welding
(i) Copper-base metals (ii) Zinc-base metals and (iii) A few types of
ferrous metals such as manganese steel and cast iron.

• The oxidizing atmosphere in these cases, create a basemetal oxide that

protects the base metal.

Oxidizing flame
The oxidizing flame has an excess of oxygen. The white cone of this
flame is small and pointed and somewhat paler than the neutral flame.

A hissing sound often accompanies this flame. This flame is not

particularly useful as it hastens oxidizing, which is not desirable
in welding.

It can, however, be used for removing carbon from molten metal,
thus softening the metal.
Oxy-acetylene welding outfit
 HOW TO PRESSURIZE (TURN ON) AN
OXYACETYLENE OUTFIT
Make sure both torch valves are off. Turn both regulator adjustment

screws counterclockwise until loose.

Slowly turn the oxygen cylinder valve on. Once open, turn the valve

all the way open to ensure proper seating without leaks.

Turn the oxygen regulator adjustment screw clockwise until the

gauge reads the desired pressure.

Open the oxygen valve on the torch to check the flowing oxygen

pressure.

Adjust if necessary and close the torch valve. Slowly open the

acetylene cylinder valve 3⁄4 to 11⁄2 turns. (Leave the wrench on

the valve if it is a wrench-style valve.)

Turn the acetylene regulator pressure adjustment screw until the

desired pressure reads on the regulator gauge.

 Open the acetylene valve on the torch briefly to make sure the

flowing pressure matches the desired working pressure.

If not, adjust the regulator until the proper pressure is reached.
CHECKING FOR LEAKS

Apply leak-detecting solution to all connections with a small brush.

(You can use soap and water so long as the soap is not petroleum based.)

If any connections cause bubbles in the solution, tighten the

connections and check again.

 Gas Welding Equipments

• Acetylene and oxygen gas is stored in compressed gas cylinders.

These gas cylinders differ widely in capacity, design and colour code.

• However, in most of the countries, the standard size of these cylinders

is 6 to 7 m3 and is painted black for oxygen and maroon for

acetylene.

• An acetylene cylinder is filled with some absorptive material, which is

saturated with a chemical solvent acetone.


Free acetylene is highly explosive, if stored at a pressure more than 200 kPa,

where it becomes very unstable and likely to explode.

Hence, acetylene needs to be carefully stored in a strong cylinder, filled with 80

to 85% porous material such as calcium silicate and then filled with acetone

which can absorb up to 420 times its volume of acetylene at a pressure of 1.75

MPa.


It is expected that the acetylene molecules fit in between the acetone molecules.
This helps in storing acetylene at a much higher pressure than

permitted when it is in free form.

Acetylene would be released from acetone at a slow rate and thus

would not form any pockets of high pressure acetylene.

The rate of release depends on the temperature of the gas.

• Acetone has the ability to absorb a large volume of acetylene and
release it as the pressure falls.

• If large quantities of acetylene gas are being consumed, it is much

cheaper to generate the gas at the place of use with the help of
acetylene gas generators.

• Acetylene is normally produced by a reaction between calcium carbide

and water which is instantaneous.
•Oxygen gas cylinders are usually equipped with about 40 litres of oxygen at a

pressure of about 154 Kgf/cm2 at 21°C.

•To provide against dangerously excessive pressure, such as could occur if the

cylinders were exposed to fire, every valve has a safety device to release the

oxygen before there is any danger of rupturing the cylinders.

• Fragile discs and fusible plugs are usually provided in the cylinders valves in

case it is subjected to danger.

 Gas pressure regulators

• Gas pressure regulators are employed for regulating the supply of

acetylene and oxygen gas from cylinders.

• A pressure regulator is connected between the cylinder and hose

leading to welding torch.

•The cylinder and hose connections have left-handed threads on the

acetylene regulator while these are right handed on the oxygen

regulator.

•A pressure regulator is fitted with two pressure gauges, one for

indication of the gas pressure in the cylinder and the other for indication

of the reduced pressure at which the gas is going out.

 Welding torch
• It is a tool for mixing oxygen and acetylene in correct proportion and
burning the mixture at the end of a tip.
• Gas flow to the torch is controlled with the help of two needle valves
in the handle of the torch. There are two basic types of gas welding
torches:
(1) Positive pressure (also known as medium or equal pressure),
and
(2) Low pressure or injector type
• The positive pressure type welding torch is the more common of the
two types of oxyacetylene torches.
Welding torch
Spark-lighter - It is used for frequent igniting the welding torch.

Filler rods - Gas welding can be done with or without using filler
rod. When welding with the filler rod, it should be held at
approximately 90° to the welding tip.

• Filler rods have the same or nearly the same chemical composition as
the base metal.

• Metallurgical properties of the weld deposit can be controlled by the

optimum choice of filler rod.
•
Most of the filler rods for gas welding also contain deoxidizers to control the oxygen

content of weld pool.


Fluxes are used in gas welding to remove the oxide film and to maintain a clean

surface.

•These are usually employed for gas welding of aluminium, stainless steel, cast iron,

brass and silicon bronze.

•They are available in the market in the form of dry powder, paste, or thick.
 Hose pipes
• The hose pipes are used for the supply of gases from the pressure
regulators.

• The most common method of hose pipe fitting both oxygen and
acetylene gas is the reinforced rubber hose pipe.

• Green is the standard color for oxygen hose, red for acetylene, and
black hose for other industrially available welding gases.
TROLLEY
• It consist a steel structure used for transporting oxygen and acetylene
cylinder from one place to another.
GOGGLES
• Welding goggles consists of blue coloured glasses and are used for
protection of eyes from harmful effects of heat and ultraviolet rays.
HOW TO SET UP AN OXYACETYLENE OUTFIT
1. Secure the cylinders in an upright position, chained to a cart or strapped
to a wall or post.
Remove the protective cylinder caps. Wipe off the cylinder valve seats,
regulator connections, and hose connections with a clean
cloth.
Crack open each cylinder valve briefly to expel any trapped dirt particles.
“Flat top” acetylene cylinders (inset) may have antifreeze in the recessed
valve seat.
Use a clean rag to remove the liquid and dry the valve seat. This style
acetylene cylinder requires a cylinder wrench to open the valve
2. Attach the regulators to the cylinders. (The acetylene connectors have left-hand
threads.)

Always hand tighten, then use a fixed wrench, not a pliers or an

adjustable wrench, to tighten. Do not overtighten—a firm seating is all that is
necessary. Attach the hoses to the regulators. The acetylene hose is red and left-
hand threaded.

The oxygen hose is green. Never use grease, oil, or pipe dope to lubricate
fittings. Grease and oil can ignite spontaneously when they come in contact with
oxygen—even without a spark or flame present.
3. Turn the regulator adjustment screws on the oxygen and
acetylene regulators counterclockwise until they are loose. (Some
regulators have a knob.)
4. Open the oxygen valve slowly all the way while standing to the side
in case the regulator gauge glass shatters.
Turn the regulator adjustment screw until oxygen begins to flow
through the hose, then loosen the regulator adjustment screw to stop
the oxygen flow. Slowly turn the acetylene cylinder valve 3⁄4 to 11⁄2
turns.
5. Adjust the acetylene regulator valve until the gas begins to flow,
then loosen the regulator adjustment screw to stop the flow.
Attach the torch to the hoses. Be sure to pressurize the system and
check for leaks before lighting.
PRE-LIGHTING CHECKLIST
Make sure torch valves are closed.
 Turn both regulator adjustment screws counterclockwise until loose.
Slowly turn on the oxygen cylinder valve all the way. Turn the
regulator adjustment to the proper pressure.
Slowly turn the acetylene cylinder valve 3⁄4 to 11⁄2 turns. Turn the
regulator adjustment valve to the proper pressure.
Some welders have been taught to open both the acetylene and
oxygen valves before lighting the torch to avoid the smoky acetylene
flame. This practice is no longer recommended.
Never light a torch with a match or butane lighter !!!!
LIGHTING THE TORCH
1. Hold the torch in one hand with the thumb and forefinger on the
acetylene torch valve.

Hold the striker in front of the torch about 3 to 6" away at a slight
angle.

Turn on the acetylene torch valve 1⁄4 to 1⁄2 turn. Immediately use the
spark lighter to light the flame
2. The flame will be yellow and smoky.
3. Put the striker down and adjust the acetylene torch valve with your
right hand so the flame is burning without producing soot. The flame
should not be separated from the torch (inset).
Open the oxygen torch valve slowly.
Adjust the oxygen to get a bright white inner flame and a bluish outer
flame.
Turn down the acetylene to eliminate the excess acetylene feather if
present.
When you have finished welding, turn off the oxygen first, then the
acetylene.
 Oxy‑Acetylene Welding Technique
• To light the flame, the acetylene valve on the torch is opened slightly
and lighted with the help of a friction spark lighter.
• The flame draws the oxygen from the atmospheric air and thus results
in a reducing flame.
• Then the acetylene valve is opened to get the required flow of
acetylene.
• The oxygen valve is then slowly opened till the intermediate flame
feather of the reducing flame recedes into the inner white cone.
• The actual adjustment of the flame depends on the type of material to
be joined

• The choice of the torch size depends on the thickness of the metal to
be joined.

• Larger torch tip sizes causes higher amount of oxygen and fuel to flow
out causing the release of more heat.

• Thus for thicker metals, larger tip radii are to be used.

Flame adjustment for oxy‑acetylene welding
• The torch tip should be positioned above the metal plate so that the white
cone is at a distance of 1.5 to 3.0 mm from the plate.

• The torch should be held at an angle of 30 to 45 degrees from the

horizontal plane.

• The torch movement along the joint should be either oscillating or circular.
In forehand welding, the torch is moved in the direction of the tip.

• This tends to preheat the metal before the white cone of the tip melts it.
• In backhand welding, the torch moves backwards. The outer blue
flames are now directed on the already welded joint.

• This allows the joint to be continuously annealed relieving the welding

stresses.

• Also backhand welding allows a better penetration as well as form a

bigger weld bead.

• Backhand welding is generally used for thicker materials.

PRE-WELD CHECKLIST

Check hoses for damage before pressurizing the system.

• Prepare metal for welding by wire brushing or sanding off mill scale
and rust. Use acetone or denatured alcohol to remove oil or other

chemical residues.

• Use fire bricks to avoid unnecessary heat loss and prevent welding to
the welding table.

• Use for appropriate tip sizes and gas pressures.

• Set up materials and clamp if necessary.

NOTE: The directions for oxyacetylene welding are for righthanded

welding. Reverse the directions for left-handed welding, or if you find it

easier to manipulate the filler rod with your right hand.

HOW TO WELD WITH OXYACETYLENE
1. Select an appropriate filler rod and lay it on the table next to the
bricks. Light the torch and adjust to a neutral flame. Pull down your
face shield.
Place small fusion tack welds at each end of the joint and in the
middle if it is a long joint. (A fusion weld uses no filler rod.)
Turn off the torch, oxygen first then acetylene, and check that your
tacked piece is still in the desired position.
If not, use a hammer to move it into position or break the tack weld
and reposition.
2. With the torch at a 45° angle to the right and oscillating the torch
in a 1⁄4 to 1⁄2" circle over both metal pieces, create a weld puddle at the
right end of your work piece.
3. When a molten puddle has formed, move the filler rod close

to the puddle and flame, but not in it.

 Begin moving slowly to the left while oscillating and maintaining

the molten puddle.

Dip the filler rod into the middle of the molten puddle and remove it,

but keep it within the heat zone.

4. Continue dipping, oscillating, and moving to the left.

As you reach the end of the weld, the cumulative heat buildup may
make it necessary to adjust to a shallower angle to deflect heat away
from the puddle and prevent burn through.

When finished, turn off the oxygen torch valve first, then the
acetylene torch valve.

The weld should penetrate to the back without burning through.

 GAS CUTTING
• The torch tip has a provision for preheating the plate as well as
providing the oxygen jet.

• Thus the tip has a central hole for oxygen jet with surrounding holes
for preheating flames.

• The cutting tip should be properly chosen for the intended

application.
Differences in torch tips for gas welding and gas cutting
• The size is normally dependent on the thickness of the plate which

determines the amount of preheating as well as the oxygen jet flow

required for cutting.

• If a larger size of orifice is used than that required, the kerf width is

wider and larger volumes of oxygen are consumed.

Tip sizes for cutting carbon steel
 Straight line cutting
• Keep the hand cutting blowpipe at 90° angle with the plate
surface and start cutting a straight line.
• Preheat the starting point to red heat before pressing the cutting
oxygen lever.
• Keep the distance between the work piece and the nozzle about 5 mm
to avoid backfire.
• Release the cutting oxygen by pressing the cutting oxygen control
lever and start the cutting action and move the blowpipe along the
punched line with uniform speed.
Inspect the cutting for:
- Uniform and smooth cut or drag line
- Straightness, sharpness.
- Width of the cut (Kerfs)
GAS WELDING MALFUNCTIONS
1. BACKFIRES
• Backfire is the condition where by the flame enters into nozzle or torch
with a violent popping sound.

• Flame either extinguishes or re – ignites at the nozzle. This common causes

of backfire

1. Weak acetylene flame.

2. The tip coming into contact with the molten pool.

3. Leaks

4. Over heating of the torch

5. Dirty tips
2. FLUSHBACK

• Flashback is the conditions whereby flame enters into torch and

travels back into supply system

• This condition can results in damage to the equipment and

serious injury to operator. Although it is possible for flame to
travel all the way back to regulator, it usually goes only as for
as the mixing chamber.
• The condition is easily identified by a sound and a thin flame of black

smoke coming from the tip.

• The causes of flashback are:

1. Improper pressure

2. Faulty mixing chamber

3. Overheating of the torch

 Safety Recommendations for Gas Welding

It is suggested that the beginner in the field of gas welding must go
through and become familiar with these general safety
recommendations, which are given below.

1. Never hang a torch with its hose on regulators or cylinder valves.

2. During working, if the welding tip becomes overheated it may be
cooled by plunging the torch into water; close the acetylene valve but
leave a little oxygen flowing.
.
3. Always use the correct pressure regulators for a gas. Acetylene
pressure regulator should never be used with any other gas.
4. Do not move the cylinder by holding the pressure regulator and also
handle pressure regulators carefully.

5. Use pressure regulator only at pressures for which it is intended.

6. Open cylinder valves slowly to avoid straining the mechanism of
pressure regulator.
7. Never use oil, grease or lubricant of any kind on regulator connections.

8. For repairs, calibrations and adjustments purposes, the pressure

regulators should be sent to the supplier.
9. Do cracking before connecting pressure regulator to the gas cylinder.
10. Inspect union nuts and connections on regulators before use to detect
faulty seats which may cause leakage of gas when the regulators are
attached to the cylinder valves.
11. Hose connections shall be well fittings and clamped properly otherwise
securely fastened to these connections in such a manner as to withstand
without leakage a pressure twice as great as the maximum delivery pressure
of the pressure regulators provided on the system.

12. Protect the hose from flying sparks, hot slag, hot workpiece and open
flame. If dirt goes into hose, blow through (with oxygen, not acetylene)
before coupling to torch or regulator.
13. Store hose on a reel (an automobile wheel) when not in use.
14. Never allow the hose to come into contact with oil or grease; these
deteriorate the rubber and constitute a hazard with oxygen.

15. Use the correct color hose for oxygen (green/black) and acetylene
(red) and never use oxygen hose for acetylene or vice versa.

16. Always protect hose from being trampled on or run over. Avoid
tangle and kinks. Never leave the hose so that it can be tripped over.
Hazards of fumes, gases and dusts can be minimized by:

Improving general ventilation of the place where welding is carried

out

Using local exhaust units, and

 Wearing individual respiratory protective equipment.

THANK YOU FOR LISTENING!!