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GAS Welding

1. The document describes the process of oxy-acetylene welding, which uses heat generated from the combustion of acetylene and oxygen gases to join metal materials. 2. It explains the chemical reactions that produce heat in the welding flame and how adjusting the oxygen flow controls the flame type. 3. An example is given of welding two mild steel sheets with an outside corner joint using the oxy-acetylene process, including setting equipment pressures and selecting a filler rod.

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170 views6 pages

GAS Welding

1. The document describes the process of oxy-acetylene welding, which uses heat generated from the combustion of acetylene and oxygen gases to join metal materials. 2. It explains the chemical reactions that produce heat in the welding flame and how adjusting the oxygen flow controls the flame type. 3. An example is given of welding two mild steel sheets with an outside corner joint using the oxy-acetylene process, including setting equipment pressures and selecting a filler rod.

Uploaded by

srija
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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BRAINWARE UNIVERSITY

KOLKATA-7000124

DEPARTMENT OF COMPUTER SCIENCE ENGINEERING

REPORT ON

OXY-ACETYLENE WELDING

:
SUBJECT CODE

NAME………………………………….

ROLL NO………………………………

YEAR…………………………………..

SESSION………………………………

SEMESTER……………………………
Oxy-Acetylene Welding

Definition:

Welding is a method of producing local coalescence of two or more similar or dissimilar


metals by achieving sufficient proximity and/or activity between them. It can be produced by the
application of heat or pressure alone or by suitable condition of the both.

Principle of oxy-acetylene welding:

Oxyfuel gas welding(OFW) is a general term used to describe any welding process that uses a
fuel gas combined with oxygen to produce a flame. This flame is the source of heat that is used
to melt the metals at the joint. The most common gas welding process uses acetylene fuel, it is
known as oxy acetylene welding and is used typically for structural sheet metal fabrication,
automotive bodies, and various other repair work. this process utilize the heat generated by the
combustion of acetylene gas(C2H2) in a mixture with oxygen(02).

The heat is generated in accordance with a pair of chemical reactions. The primary combustion
process, which occurs in the inner core of the flame (as per fig) runs as follows

C2H2+ 02= 2CO+H2+ HEAT

This reaction dissociate the acetylene into carbon monoxide and hydrogen, it produce about one
third of total heat generated in the flame. The secondary combustion process is

2C0 + H2 +1.502 = 2 CO2+H2O+HEAT

This reaction consist of the further burning of hydrogen and carbon monoxide. This second
reaction produce about two-third of the total heat. The temperature developed in the flame can
reach upto 35000 C.

Setting of flame:

To start with, when the oxyacetylene gas welding torch is ignited it (keeping the oxygen valve
off )gives an acetylene flame in which enough oxygen is drawn in from the atmosphere to burn
acetylene partially.

As the oxygen valve in the torch is progressively opened , the flame becomes generally
luminous. Then , the luminous portion contracts towards the welding tip, forming a distinct
bright zone within a blue outer envelope. This is carburizing flame (reducing flame) and has
large excess of acetylene. With further increase of oxygen content , the bright zone of the flame
contracts further and is seen to consist of two parts , a brighter inner cone and a pale green
feather trailing off its end into the blue envelope. (temperature range 30380 c )

If oxygen flow is increased gradually a certain point will reach where one will notice a distinct
change in the sound of the flame and a well defined blunt white inner cone will appear near the
tip, surrounded by a bluish envelope that is less bright. It is known as neutral flame and it is
presumed that the oxygen and acetylene gas are proportionally equal (1:1). (temperature range
32600c)Further increase of oxygen content into the mixture will give rise to an oxidizing flame,
with a sharp bluish inner cone and a hissing sound. Outer flame will be relatively shorter than
other flames. (34820c)

Equipment

1. Oxygen cylinder
2. Fuel gas cylinder(i.e. acetylene, hydrogen coal, propane, butane, LPG etc)
3. Pressure regulator
4. Hoses
5. Torch /Blow-pipe
6. Nozzle
7. Cylinder opener key
8. Spark lighter
9. Wrench
10. Filler metal
11. Flux
12. Wire brush.

personal safety

1. goggles
2. apron
3. hand-gloves
4. covered shoe
plant safety/ workshop safety

1. Fire extinguisher arrangement


2. Well ventilation

The cylinders which are used frequently in welding shop

Gas cylinder Colour coding Valve screw thread


Oxygen Black Right hand
Acetylene Maroon Left hand
Coal Red (coal gas mentioned) Left hand
Hydrogen Red Left hand
Propane Red (diameter of cylinder higher) Left hand

Argon Blue Right hand


Carbon di oxide Black with white neck Right hand
Air Grey Right hand
Nitrogen Grey with black neck Right hand
Helium Brown Right hand

Figure: cylinder arrangement in gas welding set up and acetylene cylinder cross section

Advantages of gas welding:

1. The rate heating and cooling is relatively slow. In some cases this is an advantage.
2. Since the source of heat and filler metal is separated, the welder has control over filler-
metal deposition rate.
3. The equipment low-cost , self-sufficient and usually portable.
4. Besides gas welding the equipment can be used for preheating, post heating, braze
welding, torch brazing and it is readily converted to oxy-acetylene cutting.
5.
Disadvantage of gas welding:

1. Heavy section cannot be joined satisfactorily.


2. Flame temperature is less than the temperature of the arc welding.
3. Refractory metal (tungsten, molybdenum, tantalum etc) and reactive metal ( titanium and
zirconium) cannot be gas welded.
4. More safety problems are associated with handling and storing of gases.

LEFTWARD RIGHTWARD

Gas welding job

Two mild steel sheets are welded by outside corner joint

Procedure:

 Clean the two MS sheet (100×25×2.5 mm) with wire brush


 Setting of oxy-acetylene gas welding arrangement according to the job thickness
1. Select the nozzle as per requirement = No. 3
2. Setting of working pressure of O2= 0.14kg/cm2
3. Setting of working pressure C2H2= 0.14kg/cm2
4. Selecting a copper coated mild steel (C.C.M.S.) filler
rod = 1/16 inch Dia.
Setting of job:

1. On the welding table 2 pieces of sheet are placed side by


side making an angle 90 degree with each other
2. Two tacking are made between the sheet at the end of
the edges.
3. Check the job for uniformity of the angle and reset
accordingly

Method of welding:

1. Light the torch and adjust neutral flame


2. Keep the inner cone of the flame 3 mm above the right
hand end of the joining position
3. While depositing the filler metal to make an uniform
weld pool, hold the torch at an angle 60- 70 degree and
filler rod at an angle 30 – 40 degree [leftward technique]
4. Natural cooling in air after welding.

Answer the following questions:

1. What is welding? Pen down various classifications of it.


2. Write down various tools and equipment required in gas welding process.
3. What is the gas pressure in oxygen cylinder and acetylene cylinder?
4. Why acetylene gas is dissolved in acetone.
5. Howmany time of oxy-acetylene flames are there. Mention their temperature and their
application to join various metals.
6. What is meant by “ AUTOGENEOUS , HOMOGENEOUS & HETEROGENEOUS
WELDING?

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