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Chapter1 - Gas - Welding
Chapter1 - Gas - Welding
Chapter1 - Gas - Welding
Gas Welding
1. Gas Welding
Although the oxy-acetylene process has been introduced long time ago it is still applied for its flexibility and mobility. Equipment for oxyacetylene welding consists of just a few elements, the energy necessary for welding can be transported in cylinders, Figure 1.1.
density in normal state [kg/m3]
3 4 5 8
7 1
2 9
645
oxygen propane
natural gas
air
1 2 3 4 5 6 7 8 9
oxygen cylinder with pressure reducer acetylene cylinder with pressure reducer oxygen hose acetylene hose welding torch welding rod workpiece welding nozzle welding flame
ISF 2002
flame temperature with O2 flame efficiency with O2 flame velocity with O2 43 1350
10.3 8.5 370 330
acetylene
acetylene
300
490 335
510
propane
KW k
/cm2
cm
/s
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Figure 1.1
Figure 1.2
Process energy is obtained from the exothermal chemical reaction between oxygen and a combustible gas, Figure 1.2. Suitable combustible gases are C2H2, lighting gas, H2, C3H8 and natural gas; here C3H8 has the highest calorific value. The highest flame intensity from point of view of calorific value and flame propagation speed is, however, obtained with C2H2.
natural gas
natural gas
air
propane
1.43
oxygen
0.9
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1. Gas Welding
loading funnel
cium carbide with water, Figure 1.3. Carbide is obtained from the reaction of lime and carbon in the arc furnace.
C2H2 tends to decompose already at a pressure of 0.2 MPa. Nonetheless, commercial quantities can be stored when C2H2 is dis-
grille sludge
solved in acetone (1 l of acetone dissolves approx. 24 l of C2H2 at 0.1 MPa), Figure 1.4.
to sludge pit
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Acetylene Generator
Figure 1.3
Acetone disintegrates at a pressure of more than 1.8 MPa, i.e., with a filling pressure of 1.5 MPa the storage of 6m of C2H2 is possible in a standard cylinder (40 l). For gas exchange (storage and drawing of quantities up to 700 l/h) a larger surface is necessary, therefore the gas cylinders are filled with a porous mass (diatomite). Gas consumption during welding can be observed from the weight reduction of the gas cylinder.
acetone
acetylene
porous mass
acetylene cylinder
acetone quantity : acetylene quantity : cylinder pressure : ~13 l 6000 l 15 bar
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Storage of Acetylene
Figure 1.4
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1. Gas Welding
9 Oxygen is produced by
gaseous cooling nitrogen cylinder
fractional distillation of liquid air and stored in cylinders with a filling presbundle
air
sure of up to 20 MPa, Figure 1.5. For higher oxygen consumption, storage in a liquid state and cold gasification is more profitable.
oxygen
liquid air
oxygen
pipeline liquid
compressor
separation
supply
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Figure 1.5
The standard cylinder (40 l) contains, at a filling pressure of 15 MPa, 6m of O2 (pressureless state), Figure 1.6. Moreover, cylinders with contents of 10 or 20 l (15 MPa) as well as 50 l at 20 MPa are common. Gas consumption can be calculated from the pressure difference by means of the general gas equation.
manometer
50 l oxygen cylinder
protective cap cylinder valve take-off connection
gaseous
N
p = cylinder pressure : 200 bar V = volume of cylinder : 50 l Q = volume of oxygen : 10 000 l content control Q=pV foot ring
safety valve
liquid
vaporizer
user gaseous
Storage of Oxygen
Figure 1.6
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1. Gas Welding
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In order to prevent mistakes, the gas cylinders are colour-coded. Figure 1.7 shows a survey of the present colour code and the future colour code which is in accordance with DIN EN 1089.
old condition
blue
DIN EN 1089
white blue (grey)
old condition
grey
DIN EN 1089
brown grey
are
oxygen techn.
yellow brown
helium
red red
acetylene
grey dark green grey
hydrogen
grey vivid green grey
valves
equipped with screw clamp retentions. Cylinder valves for other combustible gases have a left-hand thread-connection with a circumferential groove.
argon
darkgreen black darkgreen
argon-carbon-dioxide mixture
grey grey
nitrogen
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carbon-dioxide
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Figure 1.7
cylinder pressure
working pressure
Pressure
regulators
re-
duce the cylinder pressure to the requested working pressure, Figures 1.8 and 1.9.
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Figure 1.8
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1. Gas Welding
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At a low cylinder pressure (e.g. acetylene cylinder) and low pressure fluctuations, singlestage regulators
discharge pressure locking pressure
are applied; at higher cylinder pressures normally two-stage pressure regulators are used. The requested pressure is set by the adjusting screw. If the pressure increases on the low pressure side, the throttle valve closes the
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increased
pressure
onto
the membrane.
Figure 1.9 The injector-type torch consists of a body with valves and welding chamber with welding nozzle, Figure 1.10. By the selection of suitable welding chambers, the flame intensity can be adjusted for welding different plate thicknesses. The special form of the mixing chamber guarantees highest possible safety against flashback, Figure 1.11. The high outlet speed of the escaping O2 generates a negative pressure in the acetylene gas line, in consequence C2H2 is sucked and drawn-in. C2H2 is therefore available with a very low pressure of 0.02 up to 0.05 MPa with O2 0.3 MPa). -compared (0.2 up to Figure 1.10
welding torch head
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mixer tube
injector pressure nozzle suction nozzle welding nozzle fuel gas valve
torch body
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Welding Torch
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1. Gas Welding
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A neutral flame adjustment allows the differentiation of three zones of a chemical reaction, Figure 1.12: 0. dark core: 1. brightly shining centre cone: 2. welding zone: 3. outer flame: escaping gas mixture acetylene decomposition C2H2 -> 2C+H2 1st stage of combustion 2C + H2 + O2 (cylinder) -> 2CO + H2 2nd stage of combustion 4CO + 2H2 + 3O2 (air) -> 4CO2 + 2H2O complete reaction: 2C2H2 + 5O2 -> 4CO2 + 2H2O
pressure nozzle
torch body
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Injector-Area of Torch
Figure 1.11
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1. Gas Welding
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3200C
2500C
1800C
1100C
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Figure 1.12
welding flame
balanced (neutral) flame nozzle size: for plate thickness of 2-4 mm discharging velocity and weld heat-input rate: low 2
Figure 1.13
By changing the mixture ratio of the volumes O2:C2H2 the weld pool can greatly be influenced, Figure 1.13. At a neutral flame adjustment the mixture ratio is O2:C2H2 = 1:1. By reason of the higher flame temperature, an excess oxygen flame might allow faster welding of steel, however, there is the risk of oxidizing (flame cutting). Area of application: brass The excess acetylene causes the carburising of steel materials. Area of application: cast iron
soft flame
discharging velocity and weld heat-input rate: middle 3
moderate flame
discharging velocity and weld head-input rate: high 4
hard flame
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Figure 1.14
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1. Gas Welding
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By changing the gas mixture outlet speed the flame can be adjusted to the heat requirements of the welding job, for example when welding plates (thickness: 2 to 4 mm) with the welding chamber size 3: 2 to 4 mm, Figure 1.14. The gas mixture outlet speed is 100 to 130 m/s when using a medium or normal flame, applied to at, for example, a 3 mm plate. Using a soft flame, the gas outlet speed is lower (80 to 100 m/s) for the 2 mm plate, with a hard flame it is higher (130 to 160 m/s) for the 4 mm plate.
Depending on the plate thickness are the working methods leftward welding and rightward welding applied, Figure 1.15. A decisive factor for the designation of the working method is the sequence of flame and welding rod as well as the manipulation of flame and welding rod. The welding direction itself is of no importance. In leftward welding the flame is pointed at the open gap and wets the molten pool; the heat input to the molten pool can be well controlled by a slight movement of the torch (s 3 mm).
Leftward welding is applied to a plate thickness of up to 3 mm. The weld-rod dips into the molten pool from time to time, but remains calm otherwise. The torch swings a little. Advantages: easy to handle on thin plates
gap preparations
~ ~ s+1
denotation
symbol
r=
flange weld
welding-rod
flame
welding bead
Rightward welding ist applied to a plate thickness of 3mm upwards. The wire circles, the torch remains calm. Advantages: - the molten pool and the weld keyhole are easy to observe - good root fusion - the bath and the melting weld-rod are permanently protected from the air - narrow welding seam - low gas consumption
3,0
12,0
1-2
V - weld
1,0
8,0
1-2
corner weld
1,0
8,0
lap seam
1,0
weld-rod
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8,0
fillet weld
flame
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Flame Welding
Figure 1.15
Figure 1.16
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1. Gas Welding
onto the molten pool; a weld keyhole is formed (s 3 mm). Flanged welds and plain butt welds can be applied to a plate thickness of approx. 1.5 mm without filler material, but this does not apply to any other plate thickness and weld shape, Figure 1.16.
PB
s f
PF PG PC
welding methods all welding positions can be carried out using the oxyacetylene welding method, Figures 1.17 and 1.18
PD
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When working in tanks and confined spaces, the welder (and all other persons present!) have to be protected against the
Welding Positions I
Figure 1.17 welding heat, the gases produced during welding and lack of oxygen ((1.5 % (vol.) O2 per 2 % (vol.) C2H2 are taken out from the ambient atmosphere)), Figure 1.19. The addition of pure oxygen is unsuitable (explosion hazard!). A special type of autogene method is flamestraightening, where specific locally applied flame heating allows for shape correction of workpieces, Figure 1.20. Much experience is needed to carry out flame straightening processes. The basic principle of flame straightening de-
PA PB PF
PC
PG PD PE
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pends on locally applied heating in connection with prevention of expansion. This procFigure 1.18
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Welding Positions II
1. Gas Welding
16
ess causes the appearance of a heated zone. During cooling, shrinking forces are generated in the heated zone and lead to the desired shape correction.
Flame straightening
welded parts
Hazards through gas, fumes, explosive mixtures, electric current protective measures / safety precautions 1. requirement for a permission to enter 2. extraction unit, ventilation 3. second person for safety reasons 4. illumination and electric machines: max 42volt 5. after welding: Removing the equipment from the tank
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Flame Straightening
Figure 1.19
Figure 1.20
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