Experiment-1: Study of Gas Welding and Gas Cutting.
Objective
▪ Become familiar with Gas welding, Gas cutting
Student will be introduced to:
▪ The gas welding equipment, related tools and the essential process safety considerations
▪ Types of work materials, filler rods and fluxes
Theory
Gas Welding:
Gas Welding or Oxy-fuel gas welding is a general term used to describe any welding process that
uses a fuel gas combined with oxygen to produce a flame. The most commonly used fuel is acetylene
(C2H2) gas. The heat source is the flame obtained by combustion of oxygen and acetylene. When
mixed together in correct proportions within a hand-held torch or blowpipe, a relatively hot flame
is produced with a temperature of about 3300ºC (6000ºF). The chemical action of the oxyacetylene
flame can be adjusted by changing the ratio of the volume of oxygen to acetylene.
The combustion of oxygen and acetylene (C2 H2) is a two-stage reaction. Chemical reactions
are as follows: -
Stage 1: In the first stage, the supplied oxygen and acetylene react to produce Carbon Monoxide
and Hydrogen. Approximately one-third of the total welding heat is generated in this stage.
C2H2 + O2 = 2CO + H2 + heat
Stage 2: The second stage of the reaction involves the combustion of the CO and H2. The
remaining two-third of the heat is generated in Stage 2. The specific reactions of the second stage
are:
2CO + O2 = 2CO2 + heat
H2 + ½ O2 = H2O + heat
Figure 1: Gas Welding (Oxygen–fuel gas) process
Types of flames:
Three different types of flames can be obtained by varying the oxygen–acetylene (or
oxygen– fuel gas) ratio.
Neutral Flame: When the ratio of oxygen-
acetylene (or oxygen–fuel gas) is between 1:1
and 1.15:1, all reactions are carried to
completion and a neutral flame is produced.
As the supply of oxygen to the blowpipe is
increased, the flame contracts and the white
cone become clearly defined, assuming a
definite rounded shape. This type of flame is
the one most extensively used by the welder,
who should make himself thoroughly familiar
with its appearance and characteristics.
Oxidizing flame: A higher ratio of oxygen-
acetylene (or oxygen–fuel gas), such as 1.5:1,
produces an oxidizing flame, which is hotter
than the neutral flame (about 3600°C or
6000°F). With the increase in oxygen supply,
the inner cone will become shorter and
sharper, the flame will turn a deeper purple
color and emit a characteristic slight "hiss". An
oxidizing flame is only used for special
applications.
Carburizing flame: Excess fuel compared to
oxygen produces a carburizing flame. The
excess fuel decomposes to carbon and
hydrogen, and the flame temperature is not as
great (about 3050°C or 5500°F).
This type of flame is mainly used for hard
surfacing and should not be employed for welding
steel as unconsumed carbon may be introduced
into theweld and produce a hard, brittle, deposit.
Filler Metals & Flux
Filler metals are used to supply additional material
to the weld zone during welding. These consumable
filler metals maybe bare or flux coated. The purpose
of flux is to retard oxidation of the surfaces of the
parts being welded, by generating a gaseous shield
around the weld zone.
Gas Cutting: Gas Cutting or Oxyfuel-gas
cutting, commonly called flame cutting, is the
most common thermal cutting process. The
oxyfuel flame is first used to raise the metal to
the temperature where burning can be
initiated. Then a stream of pure oxygen is
added to the torch (or the oxygen content of
the oxyfuel mixture.
is increased) to oxidize the metal. The liquid
metal oxide and any unoxidized molten metal
are then expelled from the joint by the kinetic
energy of the oxygen-gas [Link] moving
the flame and oxygen jet (torch tip)
progressively forward, fresh metal and
oxygen are brought together forming oxide
or slag in molten form and expelling it to
form a gap, or kerf, as illustrated in figure 3.
A balance must be achieved among speed of
movement, oxygen jet size, and intensity of
flame to achieve a continuous operation.
Gas Welding/Cutting Equipment
The apparatus used in gas welding consists basically of an oxygen source and a fuel gas
source, regulators, hoses, non-return valve, check valve and torches.
Regulator: The regulator is used to control pressure from the tanks by regulating pressure
and flow rate of gas. It releases the gas at a constant rate from the
cylinder despite the pressure in the cylinder becoming less as the gas in the cylinder is used.
Hoses: The hose is usually a double-hose design i.e. there are two hose joined together. The
oxygen hose is green and the fuel hose is red.
Non-return valve: Between the regulator and hose and ideally between hose and torch on
both oxygen and fuel lines, a non-return valve and/or flashback arrestor should be installed to
prevent flame/oxygen-fuel mixture being pushed back into either cylinder and damaging the
equipment.
Check valve: A check valve lets gas flow in one direction only. Not to be confused with
flashback arrestor, a check valve is not designed to block a shockwave. A check valve is
usually a chamber containing ball that is pressed against on end by a spring. Gas flow in a
particular direction pushes the ball out of the way while no flow or flow on the other way lets
the spring push the ball into the inlet thus blocking it.
Torches: The torch is the part that the welder holds and manipulates to make the weld. It has
a connection and valve for Oxygen and also a connection and valve for Fuel, a handle for
grasp, a mixing chamber for mixing of the fuel and oxygen, a tip where the flame forms. A
welding torch head is used to weld metals and can be identified by having only two pipes
running to the nozzle and no oxygen blast trigger. A cutting torch head is used to cut metals
and can be identified by having three pipes that go to an around 900 nozzle and also by oxygen-
blast trigger that provides oxygen to blast away material while cutting.
Figure 5: welding torch.