OXYGEN-FUEL GAS WELDING

GROUP 2
AGUILAR, JOSHUA JOHN
CAJURAO, CHRISTINE JOY
DE LOS REYES, NICALYN
ENCINAREZ, ERWIN
MONTENEGRO, RIEJHON
PALACIOS, KEVIN
SUMAYO, CHRISTIAN
 INTRODUCTION
Oxyfuel gas welding is a process that joins metals by combustion of a fuel gas,
oxygen, and air mixed in a nozzle and directed at the work surface. The most common fuel
gas used is acetylene. The fumes generated in this type of welding originate from the base
metal, filler metal, and fluxes. However, the fume levels are minimal and the
temperatures produced are much lower than during arc welding. This process is often
used for auto body and home repair because the cost of equipment is low. It is not used to
a large extent commercially because the weld quality is inferior to that of arc welding
processes. The technique also may be applied to cutting rather than joining of metal (e.g.,
oxyfuel cutting). The chemical action of the oxyacetylene flame can be adjusted by
changing the ratio of the volume of oxygen to acetylene.
ADVANTAGES DISADVANTAGES

● Low capital cost ● Primarily limited to mild and low alloy

● No electrical requirements steels
● Consumable costs low ● Less suitable for stainless steels and
● Can be used manually or aluminum
mechanised ● Wide HAZ
● Transportable ● Quality influenced by parameters and
● Can be used to cut thick sections torch nozzle and plate surface
● All positions condition
EQUIPMENT & ACCESSORIES
Essential equipment components

Torch
The basic oxyacetylene torch comprises:
● Torch body (or handle)
● Two separate gas tubes (through the handle connected to the hoses)
● Separate control valves
● Mixer chamber
● Flame tube
● Welding tip

The cutting torch requires two oxygen supplies to the nozzle, one mixed with fuel gas for
preheating and a separate oxygen flow for cutting.
Hoses

Hoses between the torch and the gas regulators should be colour-coded; in the UK: red for acetylene,
and blue for oxygen. Fittings on the oxygen hose have right-hand threads; while those on the acetylene
hose have left-hand threads.

Gas regulators

The primary function of a gas regulator is to control gas pressure. It reduces the high pressure of the
bottle-stored gas to the working pressure of the torch, and this will be maintained during welding. The
regulator has two separate gauges: a high pressure gauge for gas in the cylinder and a low pressure
gauge for pressure of gas fed to the torch. The amount of gas remaining in the cylinder can be judged
from the high pressure gauge. The regulator, which has a pressure adjusting screw, is used to control
gas flow rate to the torch by setting the outlet gas pressure.
Flame traps

Flame traps (also called flashback arresters) must be fitted into both oxygen and acetylene gas lines
to prevent a flashback flame from reaching the regulators. Non-return spring-loaded valves can be
fitted in the hoses to detect/stop reverse gas flow. Thus, the valves can be used to prevent conditions
leading to flashback, but should always be used in conjunction with flashback arresters.

A flashback is where the flame burns in the torch body, accompanied by a whistling sound. It will
occur when flame speed exceeds gas flow rate and the flame can pass back through the mixing
chamber into the hoses. Most likely causes are: incorrect gas pressures giving too low a gas velocity,
hose leaks, loose connections, or welder techniques which disturb gas flow.
Identification of gas cylinders
Gas cylinders are colour-coded. In the UK, an oxygen cylinder is black with a
white/grey shoulder; and an acetylene cylinder is maroon. Cylinders should also carry a
label that gives details of the type of gas.

Oxygen and acetylene are stored in cylinders at high pressure. Oxygen pressure can
be as high as 300 bar. Acetylene, which is dissolved in acetone contained in a porous
material, is stored at a much lower pressure, approximately 15bar.

It is vitally important to ensure that the regulator fitted to the oxygen cylinder is
rated to at least the same pressure as the cylinder. Some oxygen regulators are only rated
at 215 bar and should not be used on a 300 bar cylinder. Flammable gases such as
acetylene (and propane) have left hand threads on the cylinder and regulator; the oxygen
regulator and cylinder have a conventional right hand thread. On no account should oil or
grease be allowed to come into contact with oxygen equipment.
Typical gas pressures and flow rates for C-Mn steel:
Selection of correct nozzles

Welding torches are generally rated according to thickness of material to be welded. They
range from light duty (for sheet steel up to 2mm in thickness) to heavy duty (for steel plate
greater than 25mm in thickness). Each torch can be fitted with a range of nozzles with a bore
diameter selected according to material thickness. Gas pressures are set to give correct flow rate
for nozzle bore diameter. Proportions of oxygen and acetylene in the mixture can be adjusted to
give a neutral, oxidising or carburising flame. (See the description of oxyacetylene processes)
Welding is normally carried out using a neutral flame with equal quantities of oxygen and
acetylene.
Arc processes and applications

The applications of gas welding include welding and cutting metals. Below is the used gas
welding:

● Joining of ferrous and nonferrous metals

● oxyacetylene welding can be used for joining carbon steels, alloy steels, cast iron,
aluminum, and its alloys, copper and its alloys, nickel, magnesium, etc.
● Widely used in automotive and aircraft industries.
● oxyacetylene welding applications are used in sheet metal fabricating plants. finally,
● Can join materials that require a relatively slow rate of heating and cooling.
Electrode codes

Gas welding has no codes, Because in gas welding they use filler rod and the filler rod has no classification
codes in ASM, AWS, and BS.
Common weld and defects

Often acetylene welding issues occur when one of the basics wasn’t performed properly. This
includes:

● Only weld bare metal with all paints, oils and rust removed
● Fit metal parts before welding
● A welding jig table might be needed to secure the project
● Firm clamping in position
● Selection of correct gas pressure based on tip selection
● Right speed of travel (fast or slow can result in issues such as burning or a poor bead – see
illustration )
Defects

● Slag Inclusion
● Porosity
● Welding Cracks
● Incomplete Fusion
● Undercut
● Incomplete Penetration
 References

https://www.twi-global.com/technical-knowledge/job-knowledge/equipment-for-oxyacetylene-
welding-013?fbclid=IwAR0XoHKIAWMcl8TR2zfD0oppzdOQzgS-
Q3Hos8zsUDhWia3hCy1aZzWHLbo

https://studentlesson.com/gas-welding-definition-applications-working-advantages-
disadvantages/?fbclid=IwAR3aFhogQ2EuzJ2D9GSsxJaQvWUyeBBM2FV8ZyL9uX4MqenQqqh8rvZ4
TzU

https://weldguru.com/weld-troubleshooting/?fbclid=IwAR2-
ALeSUw50x6zTPxHdk4J1jbPOh8Fm0YqT3h-cOPlmp_omBajwGt7SkYI

https://l.facebook.com/l.php?u=https%3A%2F%2Fwww.sciencedirect.com%2Ftopics%2Fengineering%
2Foxyfuel%3Ffbclid%3DIwAR3qPY5dg9VGSVo4adlnPX3xWXPkeI-
LtD_GDIg12Ku6sprNLysmeH7rark&h=AT27CpiioepPp86WK4Y3ETYZUGWQNvpzpVQuS920pBAy3
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