Gas Welding Final Lab

MPD252
Casting & Welding 2
Lab 1 - " Gas Welding"
Supervised by: Dr. Ramadan Aljmusy

Eng. Basem Tarek
Names: Omar Alaa Eldin Mohamed18p9390
Seif Khaled 21P0143
May Fadl Helil 18P8064

Contents
1. Introduction...................................................................................... 3
2.1 Fusion welding: .......................................................................... 3
2.2 Gas welding: .............................................................................. 3
2. Oxyfuel: ........................................................................................... 4
2.1 introduction: ............................................................................... 4
2.2 types of flames. .............................................................................. 4
3. Flux: ................................................................................................ 6
3.1 Why we use flux: ............................................................................ 6
3.2 How it protects the weld pool: ......................................................... 6
3.3 Material used: ................................................................................. 6
 Potassium .................................................................................. 6
 Lithium ....................................................................................... 6
 Sodium ...................................................................................... 6
 Borax ......................................................................................... 6
4. Techniques of welding: .................................................................... 6
4.1 Leftwards or forehand: ............................................................... 7
4.2 Rightwards or Backhand: ........................................................... 7
5. Advantages: .................................................................................... 7
6. Disadvantages: ................................................................................ 8
7. Application: ...................................................................................... 8
1
Table of figures
Figure 1 gas welding............................................................................................ 4
Figure 2 Carburizing flame .................................................................................. 5
Figure 3 Neutral flame ......................................................................................... 5
Figure 4 oxygen flame ......................................................................................... 6
Figure 5 leftward direction ................................................................................... 7
Figure 6 Right Direction ....................................................................................... 7
2
1. Introduction
2.1 Fusion welding:
Fusion welding is a type of welding that melts metals to join them when
they're similar. This creates a zone in the material affected by the heat.
The metals are joined while in a liquid state, without pressure, by molten
metal connecting them. Heat is produced through chemical reactions,
electric resistance, electric arcs, or power beams.
Fusion welding finds wide applications in producing everyday items like

airplanes, cars, and structures. It's also popular among artists who use
both arc and flame welding techniques for creating artwork. Fusion welding
comes in various forms including spot, seam, and projection welding, as
well as oxyfuel gas welding and Thermit welding. Additionally, there are
techniques like GMAW, MMAW, SAW, and GTAW, along with laser and
electron beam welding methods.
2.2 Gas welding:
Gas welding is a method where metal is heated until it melts, allowing it to

join or fuse with other metals through a flame created by a chemical
reaction between fuel gas and oxygen. This process can involve the use
of filler or be done without it, and it can also be performed with or without
applying pressure. Additionally, gas welding is capable of brazing
dissimilar metals together.
3
2. Oxyfuel:
2.1 introduction:
It employs an oxyfuel flame generated by the combustion of acetylene fuel

and oxygen gas in the weld torch, constituting a chemical reaction serving
as the heat source. This method is favored due to its exceptionally high
flame temperature, reaching up to 3500 degrees Celsius.
Figure 1 gas welding.
2.2 types of flames.
The flame is created by burning a mixture of acetylene and oxygen. Metal

fusion is accomplished by directing the inner cone of the flame onto the
metal. Additionally, oxyacetylene can be utilized for metal cutting
purposes.
4
• Carburizing Flame:
When oxygen is turned on, the flame transforms into

a long white inner area known as the "Feather,"
encircled by a transparent blue envelope, which is
termed the Carburizing flame. This flame is achieved
by utilizing an excess amount of acetylene, resulting
in a reduced flame. The combustion of acetylene
becomes incomplete, appearing greenish between
Figure 2 Carburizing flame
the inner cone and the outer envelope. This type of
flame is particularly suitable for welding aluminum alloys and high-carbon
steels.
• Neutral Flame:
By adding a slightly higher amount of oxygen, a bright
whitish cone is formed, encased within a transparent
blue envelope. This type of flame maintains a balance
between fuel gas and oxygen. It is commonly employed
for welding various materials including steels, aluminum,
copper, and cast iron. In this type of flame, acetylene and
Figure 3 Neutral flame
oxygen are mixed in equal proportions and burn at the
tip of the welding torch. The inner cone generates approximately two-
thirds of the heat, while the outer envelope contributes the remaining one-
third of the energy.
5
• Oxidizing Flame:
When an additional amount of oxygen is introduced, the

flame's cone darkens and becomes more pointed, while
the envelope shortens and intensifies. This type of flame
exhibits the highest flame temperature. Primarily, it is
Figure 4 oxygen flame
employed for welding brass and for brazing operations
3. Flux:
3.1 Why we use flux:

During the fusion of metal, oxygen from both the atmosphere and the
torch can combine with the molten metal, potentially leading to defective
welds. To mitigate this issue, flux can be utilized 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
 Sodium
 Borax
4. Techniques of welding:
6
4.1 Leftwards or forehand:
This welding technique is employed for
joining various types of joints such as butt
welds, lap joints, and fillet joints. It is
particularly suitable for metals with
thicknesses up to 5mm. Additionally, the
torch is positioned at a relatively high angle,
Figure 5 leftward direction
typically ranging from 60 to 70 degrees.
4.2 Rightwards or Backhand:
This method is applied for welding plates

with thicknesses exceeding 5mm due to its
low angle, typically ranging from 40 to 50
degrees. This angle allows for preheating
the metal before welding. It is also suitable
Figure 6 Right Direction
for welding in flat, horizontal, and vertical
positions of the workpiece.
5. Advantages:
• Simple equipment
• Portable
• Inexpensive
• Easy for maintenance and repair
7
6. Disadvantages:
• Limited power density
• 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. Application:
The oxy-acetylene flame is utilized for welding metals with high melting
temperatures, such as mild steel and high carbon steel. Conversely, the
oxy-hydrogen flame is employed for welding metals with lower melting
temperatures, such as aluminum, lead, and magnesium.

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MPD252

Casting & Welding 2

Lab 1 - " Gas Welding"

Supervised by: Dr. Ramadan Aljmusy

Names: Omar Alaa Eldin Mohamed18p9390

Seif Khaled 21P0143

May Fadl Helil 18P8064

2.1 Fusion welding: .......................................................................... 3

2.2 Gas welding: .............................................................................. 3

2.1 introduction: ............................................................................... 4

2.2 types of flames. .............................................................................. 4

3.1 Why we use flux: ............................................................................ 6

3.2 How it protects the weld pool: ......................................................... 6

3.3 Material used: ................................................................................. 6

4. Techniques of welding: .................................................................... 6

4.1 Leftwards or forehand: ............................................................... 7

4.2 Rightwards or Backhand: ........................................................... 7

Fusion welding finds wide applications in producing everyday items like

2.2 Gas welding:

Gas welding is a method where metal is heated until it melts, allowing it to

It employs an oxyfuel flame generated by the combustion of acetylene fuel

Figure 1 gas welding.

2.2 types of flames.

The flame is created by burning a mixture of acetylene and oxygen. Metal

When oxygen is turned on, the flame transforms into

When an additional amount of oxygen is introduced, the

3.1 Why we use flux:

3.2 How it protects the weld pool:

3.3 Material used:

4.2 Rightwards or Backhand:

This method is applied for welding plates

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