To investigate and study gas welding, filler material used,

different types of gases and oxidizing, reducing and normal flame

1. Objective
In this experiment we are going to study about gas welding, its filler material and different
types of flames.

2. Apparatus
 Pressure gauges
 Hoses
 Control valves
 Torch
 Nozzle
 Oxygen cylinder
 Acetylene cylinder

Fig.1 Gas welding schematic

3. Procedure
 By using chuck key, open the acetylene-regulator adjusting screw, about quarter to
half turn.
 Repeat the same procedures to the oxygen cylinder but open the adjusting screw
about half to one turn.
  Adjust the pressure gauge on the acetylene cylinder about 5- 8 psi and for the
oxygen cylinder is about 10 - 20 psi.
 Used sponge with a foam to check any leakage n fluid lines and fittings of both
cylinders.
 to light the torch, open the acetylene valve on the torch handle about 1/6 turn and
ignite the gas with a flint lighter.
 Continue opened the acetylene needle valve until all the heavy black smoke clears
from the flame.
 Slowly open the oxygen valve on the torch until the flame became oxidizing.
 Preheat the work piece toughly first.
 Heat the area to be weld until it turns red.
 Apply the filler rod to the melted area.
 After the work is done shut off the flame by closing the acetylene needle vale and
continue by closing oxygen needle valve.
 Close the acetylene regulator adjusting screw and continue by close the oxygen-
regulator adjusting screw.
 Hang up the torch and hose properly to prevent hose or torch damage.

Theory
4. Gas welding
Gas welding is the type in which one of the components is the oxygen while the other
component can be any gas but, in most cases, it is acetylene. Basic purpose if this welding is
to cut or melt the workpiece. In this welding oxygen is usually used instead of the air. It will
produce a higher temperature to melt or cut the material. Temperature of the oxy-
acetylene flame is about 3500 degree Celsius. Oxy-acetylene welding is still used for metal-
based artwork and in smaller home-based shops, as well as situations where accessing
electricity (e.g., via an extension cord or portable generator) would present difficulties. The
oxy-acetylene (and other gas mixtures) welding torch remains a mainstay heat source for
manual brazing and braze welding, as well as metal forming, preparation, and localized heat
treating. In addition, gas cutting is still widely used, both in heavy industry and light
industrial and repair operations.
Fig.2 Arc welding plant

4.1. Principle
Basic principle of the gas welding is somehow like the principle of the spot welding. In this
welding we heat up the base metal and electrode with the help of current so that they melt
and merge with each other so that on cooling they can be attached with each other. At the
same time when the metal melts the filler metal is filled so that they can be mixed with each
other rand we can get a good weld.

4.2. Ohm’s law

Ohms law provides us with the relation between the voltage and current.
It states that the current that is passing through the conductor is directly proportional to the
voltage by introducing a constant of proportionality that is resistance.
V
I=
R
R shows the resistance which is the opposition to the flow of the current.
I am in amperes and V is in volts whereas R is in ohms.
According to the ohms law resistance is independent of the current. Due to this resistance
heat is produces in the fire or in any circuit path. This produced heat can be determined by
the formula:

H=I 2 Rt

4.3. Filler material

We can define filler metal in such a way that sometimes there are certain gaps which are
created in the weld. So, to fill these gaps we can use filler meatal to complete these gaps
and create a good weld.
i. Advantages of filler material
 Filler metal is used avoid cracks to give a final good weld
 Basic purpose for the filler metal s to fill the gap between the weld
ii. Disadvantages of filler material
 Joint in which the filler material is required has some built in gap due to which its
strength is reduced
 Strength of joint with filler metal is relatively less than the weld without any filler
metal

4.4. Welding gas

Welding gases can be defined as the gases which are used in the welding process for cutting
and welding different types of metals.
i. Advantages of welding gases
 By using different types of welding gases, we can get the welding flame of our
required needs.
 We can get reducing flame by using different types of welding gas so we can
easily control the flame

4.5. Types of flame

 Oxidizing flame
Oxidizing flame can be defined as the flame with excessive amount of oxygen. It results in
the shorten of flame color also darkens and roars. Oxidizing flame has characteristic to
oxidizes the surface.

 Reducing flame
We can define reducing flame as the flame which have low content of oxygen. Reducing
flame is usually yellowish in color which indicates the presence of the carbon or
hydrocarbon contents.
  Neutral flame
We can define neutral flame as the flame of mixture of gases which have equal content of
oxygen and other gas. It means amount of oxygen is precisely enough and there is no
oxidation or reduction.

5. Advantages of gas welding

 Cost-Equipment o the arc welding is affordable and not too expensive.
 Portability-Arc welding plant is compacting size and we can transport the plant
from one place to the other easily.
 Unlike other welding this type of welding can be used on the dirty metals
whereas other welding cannot be easily used on the dirty materials.
 Shielding gas-In other welding we must have to cover the surface with some type
of shielding gas.

6. Disadvantages of gas welding

Regardless of certain advantages there are some disadvantages of the gas welding:

 Lower efficiency is one of the basic disadvantages of the gas welding. The reason
of less efficiency is due to extra loss of material in the gas welding than any other
type of the welding
 To operate gas welding plant, we require operator with skills and training
 There is a disadvantage of using gas welding is that it can be used only on the
thin metal. It cannot be used on thick materials.

7. Limitations of gas welding

 Arc welding is sensitive to the contaminants like rust, mill scale, dirt and oil paint.
These can cause porosity, incomplete fusion and bad appearance
 Lack of fusion is also another limitation for the arc welding due to which we often
resist to use arc welding
 Arc welding is an open process due to which there could be a skin contact which
a cause damage to the skin.

8. Applications in Pakistan
 Miller synchro wave
 Miller maxter
 Miller Dynasty
 Miller gold star series

9. Steps of operation
Following are the steps for the arc welding:

 Clean up the face of metal

 Set up the workpiece
 Adjust your welding plant
 Turn on the plant and weld the workpiece
  Fill the remaining metal with the beads weld

10. Precautionary steps

There is certain precautionary measure which we must take before using spot welding
which are as follows:

 Helmets with shields so that it can protect bus from UV radiations which will
cause certain chemical burns
 Goggles or glasses are necessary s that there should be no damage to the eyes
 We should wear closed shoes to prevent any contact of the fire or workpiece
with our foot
 Our clothes should be skin fit, clothes not should be too losing that they can be
captured by the machine

11. Comments
At the end of the experiment, as we know:

 The problem that occurs on the metal in neutral weld process.

 How to weld with correctly.
 Three type of different flame.
How to start or setup the regulator valve with correctly