Oxy-acetylene welding

Mohd nazreen Hafiz hazam Ahmad syimir

Definition and explanation

A process to joining to pieces of metal in which the required high temperature is obtained by the combustion of acetylene gas and oxygen. The gases are thoroughly mixed in the nozzle or tip of the welding torch to ensure perfect combustion. the weld may be formed directly between two adjoining surface, but usually metal from a welding rod is fused in between the surfaces of the joint.

Oxy-acetylene welding complete equipment:

Oxygen gas cylinder

Acetylene gas cylinder

Oxygen pressure regulator

Acetylene pressure regulator

Oxygen gas hose (blue)

Acetylene gas hose (red)

Welding torch blow pipe with a set of gas lighter

Trolleys for the transportation of oxygen and acetylene cylinders

The usage and example

Oxy-gas

Explain the types, working principals, usage and function

Welding regulators  The pressure of the gases obtained from cylinders/generators is considerably higher than the gas pressure used to operate the welding torch.The purpose of using a gas pressure regulator is, therefore (i) to reduce the high pressure of the gas in the cylinder to a suitable working pressure, and (ii) to produce a steady flow of gas under varying cylinder pressures.

 A pressure regulator is fitted with two pressure gauges. One indicates the gas pressure in the cylinder and the other shows the reduced pressure at which the gas is going out. A pressure regulator is connected between the cylinder/generator and the hose leading to welding torch. Gas pressure regulators may be classified as: 1. Single stage Regulator 2. Two stage Regulator.

Oxy-acetylene hoses
The hose for the supply of oxygen (from the pressure regulator) to the welding torch is coloured blue and has right handed thread connections, whereas the acetylene hose is coloured red and has left handed thread connections with chamfers or grooves on the nuts. For welding purposes, the hoses to be used should be strong, non- porous, flexible and not subject to kinking. Welding hose has a seamless lining which is manufactured from rubber (or a rubber compound) which is reinforced with canvas or wrapped cotton plies. The hose is resistant to the action of gases normally used in welding. The outer casing is made of tough abrasion resistant rubber. The hose is very robust and capable of withstanding high pressure.Some precautions are to be taken when using reinforced rubber hoses: (i) Only one gas should be used in a hose. For example, using an oxygen hose to carry acetylene could cause a serious accident. (ii) The hose should never be patched or repaired. (iii) Hot metal (job) should never be placed on the hose

 Oxy-acetylene welding torch Oxygen and the fuel gas having been reduced in pressure by the gas regulators are fed through suitable hoses to a welding torch which mixes and controls the flow of gases to the welding nozzle or tip where the gas mixture is burnt to produce a flame for carrying out gas welding operation. High pressure torches are used with (dissolved) acetylene stored in cylinders at a pressure of 8 bar. Low pressure blowpipes are used with acetylene obtained from an acetylene generator at a pressure of 200 mm head of water (approximately 0.02 bar).

 welding torches are constructed with pressure-forged brass in the rear body to provide an excellent strength-to-weight ratio, silver-brazed joints for high rigidity and resistance to gas leakage, and swaged copper tips for maximum heat and wear resistance. Separate heavy-walled seamless brass tubes minimize the possibility of gases mixing within the handle and an exclusive coiled oxygen tube resists flashbacks. Gas Apparatus Lifetime Warranty applies to Oxweld, Purox and Prest-O-Lite standard torches, regulators and flowmeters and covers manufacturer defect in materials and workmanship as well as normal wear and tear

 Oxy-acetylene welding tip

Oxy-acetylene manifold system and single station system

In an industry where considerable gas welding is done and at several places or where rate of gas consumption is high, it is much advantageous to use a manifold system. In a manifold system, instead of having gas cylinders at each place of work, they are assembled at one centralised position in specially designed racks and connected by a manifold. The gas is then distributed by means of a pipeline to different workplaces.

Brazing and braze welding process

Brazing  Brazing is a meta-joining process where by a filler miller is heated above and distributed between two or more close-fitting parts by capillary action  The filler metal is brought slightly above its melting (liquids) temperature while protected by a suitable atmosphere, usually a flux.  It then flows over the base metal (known as wetting) and is then cooled to join the work pieces together .  It similar to soldering, except the temperatures used to melt the filler metal are above 450 calcius