GAS WELDING 22.0 General Gas welding is a fusion welding process. Here hi air and a gas (such as acetylene, hydrogen, butane, methane petroleum gas etc.) is used to join metals, A flame is produced when the mixture of gases are ignited. This flame has a very high temperature which melts and fuses the metal parts, The quantity of gases are to be regulated for controlling the weld flame. A filler metal rod is used to supply molten metal at the joint, [Lis used for repair work, for joining thin walled parts of steel and non-ferrous alloys. at generated by the combustion of oxygen or 22.1 Chemical Reactions in Oxy-Acetylene Flame The details of reaction involved at each step and the final equation is given below. Fig. 22.1 shows the flame details. Zone 2 Redu: Zone |: Inner luminous zone g zone Zone 3 Oxidizing zone Outer flame Torch wt rig Itt mab} 35 the mm H+ 15x 1 13150°C 3000 2 o.} 2000 é 160°C iB 1000 Extent of fame ———> ig. 22.1. : Gas Flame DetailsGas Welding 331 First acetylene is decomposed to C and H Decomposition of 2C,H <————— 4C + 2H, Zone l Acetylene ‘Then the carbon combines with oxygen to form CO due to partial combustion Incomplete combustion 4C + 20,42 4CO + heat Zone Il Combustion of carbon Finally CO is converted to CO, due to complete combustion Combustion of COtoCO, = 4CO+2H,#30274CO, 42,0 Zonelll ere oe H,+50,—— 4CO+2H,0+31,000 Cal/mole Water Vapour ey Adding we get, Zone 1: Consists of decomposed products of C,H. A truncated cone flame with rounded end is formed. Solid carbon particles are formed which are incandescent, glow with the brightest flame. It is the inner luminous cone. Heat is evolved mainly due to oxidation of C to CO at a distance of 3~Smm from the end of the inner cone. Zone I ‘Temperature is the highest in this zone greater than 3000°C In this reducing zone, the products of combustion CO and H, can reduce oxides. Zone IIL: In this oxidizing zone, CO is burnt and H, is converted to water vapour with a surplus O, from air 22.2 Gas Torch A gas torch is required for gas welding. The details of the gas torch are given below. A metal tube ‘P’ is attached with a detachable end ‘A’. This end carries a mixing chamber “B’ for mixing the gases. The mixer is connected to a metallic tube called the tip. To the tip is attached a nozzle through which gas mixture comes out. Tube ‘P” has separate passages for the entry of O, and C,H, The passages are connected to the gas cylinders through separate hard rubber hose tubes. ‘The quantity of gas can be controlled by valves, independently. The pressure of gases are controlled at the cylinder end by operating the regulator and observing the gauges meant for the purpose. O, enters through the central hole and C,H, enters through the outer holes in the mixing chamber. 0, gas is delivered at pressures approximately 0,17 N/mm*. C,H, gas is delivered at pressures 0.07 7 0.1 N/mm?, Fig. 22.2 shows Gas torch details. ‘332 Manufacturing Process ~| Hole Inner....0, Outer...CH, Metal Tube aa" Mixer Ty toe? 2 Nozzle Fig, 22.2 + Gas Torch Details 22.3 Oxy-acetylene Welding When acetylene is mixed with oxygen in correet proportion and ignited a flame is produced The flame will have a temperature of about 3200°C, A Gas torch is used for the purpose. Acetylene gas is let out through the torch and ignited first..The gas catches fire and a flame is produced Oxygen is then let out to sustain the flame. By regulating the control valves the quantities of both the gases can he adjusted so that desired flame is produced. Three types of flames can be produced. Gas Torch is used for welding hence is referred to as welding torch also 1. Neutral flame : Oxygen :Acetylen Approximate volume of gases are in equal proportions. Temperature of the flume is about 3260°C. Flame is light blue in colour. Itis surrounded by outer flame produced by the combination of oxygen and CO, H, in the inner zone. This type of flame does not bring about any chemical change in the molten metal. This type of flame is used for welding Mild Steel, Cast Iron, Aluminium, Copper and Stainless steel. This is the correct flame for welding. 2. Oxi ‘After establishing neutral flame, if the oxygen content is further increased the resulting flame is oxidising in nature. The flame will be small short cone, dark blue in colour and more pointed than in the first case. The outer envelope is much shorter than the first. The temperature rise is as high as 3480°C. Oxygen : Acetylene i: 1.5:1. The excess oxygen at high temperature tends to combine with many metals to form hard, brittle low strength oxides. Hence, this type of flame finds limited use in welding. A slightly oxidising flame is used in welding Copper base alloys, Zine buse alloys, wherein preferential oxidation of the one of the elements provides a protective layer. ing Flame 3, Reducing Flame After establishing neutral flame, if the volume of acetylene gas is increased then the resulting flame is reducing in nature, The outer flame envelope is longer than that of neutral flame and is usually much brighter. A reducing flame does not completely consume the available carbon, therefore the temperature is lower and the un-consumed carbon is forced into the molten metal. Oxygen : Acetylene :: 121.5. A reducing flame ensures the absence of oxidation, metals that tend to absorb carbon should not be welded with this flame. Ex. Non-ferrous metals, High carbon steels. A carburizing flame contains excess acetylene than a reducing flame,GasWelding 333 The details are shown in Fig. 22.3 Neutral Flame Inner'Cone Outer Envelope Inner Cone Outer Envelope (Pointed) Carburizing Flame Bright luminous inner code Blue envelope Acetylene feather Fig. 22.3 : Types of Flame 22.4 Oxy-acetylene Torch Cu 9 O,—C,H, gas torch can be used to cut ferrous metals whenever ferrous metals (iron or steel) atelevated temperatures are exposed to continuous blast of ,, The iron in the metal starts oxidising and melts continuously. This is due to the high affinity of Fe for O, at high temperatures, O, combines with Fe and forms its oxides and is removed as slag, on cooling. The slag will be very brittle and can be easily chipped off. The metal is cut easily. To start with the metal is heated to red hot by oxy acetylene flame or other means. Now a jet of oxygen is passed on the metal, through the centre hole of the torch. The metal starts melting and the slag formed is removed by hammering, crow bar cic, the metal is cut, This method is used generally for cutting Riser portion in steel castings, dressing of ingots, washing skulls in the ladle ete. 22.5 Oxy-Hydrogen Gas Welding Hydrogen gas is used here in place of acetylene. The maximum temperature that can be realised is 2500°C. This is best suited for welding thin sheets, low melting alloys and for brazing work. No oxidation of metal takes place for reducing flames 22.6 Air Acetylene Welding Airis used in place of oxygen, Low melting alloys can be welded. Ex. Lead. Low temperature brazing. Soldering. Temperature realised is less than 100°C. Acetylene is drawn through a eylinder nd air is drawn from the atmosphere.334 Manufacturing Process —1 Acetylene when stored under pressure may become unstable at elevated temperatures. Hence compressed C,H, is dissolved in acetone (or a filler saturated with acetone). This is referred to as Dissolved Acetylene (DA). Acetone can absorb about 25 times its own volume of acetylene under atmospheric pressure and forms a spongy mass. Thus C,H, gas is prevented from dissociation. 22.7 Gas Welding Advantages : © Controlling temperature is easy * Since source of heat and filler metal are separate, control of metal deposition is easy. © Quantity of O, and C,H, gases * Initial cost of equipment low. can be independently controlled for good welding. © Maintenance cost low. *£ Equipment portable (gas torch is easy to carry). maintenance. © Can be used for preheating the metal, used as oxygen ~ cutting lane, for brazing. Disadvantages = © Cannot be used for heavy sections. # Flame temperature is less than the are temperature. * Refractory metals like W, Mo etc. cannot be gas welded. * Takes more time to heat metal. © Gases are expensive. Application : * Joining thin sections. ‘© Most of the ferrous and non-ferrous metals can be gas welded. Automobile and air craft industries in sheet metal joining. Gas welding can be carried out in two ways and are referred to as leftward and rightward welding. These are also referred to as forward welding and backward welding, In the following ‘araph, the difference is given Fig. 22.4 shows the details 22.8 Difference between Forward and Backward Welding Leftward / Forward Welding Rightward / Backward Welding 1. Welding operation is done by working 1. Welding operation is done by from right to left working from left to right 2. The torch is held between the filler rod 2. The filler rod is held between weld and the weld. and flame of torch.Gas Welding 335 3. The angle of torch is between 60°- 70° 3. The angle of torch is 40° - 50” w.rt. horizontal to ensure less obstruction want. horizontal to ensure less to the operator. obstruction to the operator. 4, Due to oxidation of metal, the weld is 4. Due to non oxidation of metal, not so strong, tough and dense Weld is quite strong, tough and dense. 5. Torch is given sideways movement for 5. No need of sideways movement effective welding. to torch for welding 6. This type of welding is used for low 6. This type of welding is normally used melting point metals. for thicker sections. 7. Acetylene requirement 7. Acetylene requirement 100-120 lit/hr 120-150 livhr Leftward/Forward Rightward/Backward welding welling’ ay — & ane § so-so" — 0 70" sua 3040" be ig” i iN St ig.22.4 : Types of welding Forward and Backward Welding Summary Forward Welding © ‘Torch is given sideways movement «The filler rod is moved steadily without any sideways movement # Since the weld is exposed to atmosphere for a short internal oxidation of the weld may take place Backward Welding © The torch and rod make angles of between 40° - 50° and 30° - 40° respectively with the plane of the plate. * Backward welding provides better shielding against atmospheric oxication of the weld metal 22.9 Filler Rod Itis a metal rod of diameter 5 the required metal at the joint. It's composition will be the same as that of the parent metal. It is also referred to as welding rod. Bare metal rods are called filler rod, Coated metal rods are called coated electrode or electrodes. Electrodes are normally used in are welding. Filler rods are used in gas welding. 12 mm and upto 450 mm length, It is used in welding.to supply336 Manufacturing Process -1 Electrodes can be > Non consumable type- Electrode is not consumed here. Ex. Carbon, graphite, tungsten, > Consumabletype — Electrodes are consumed here. Electrodes are made of metals such as steel, Cu, Bra depending upon the parent metal being welded. 8, AL., etc. Electrode coating is made of 80 ~ 85% chalk + 15 — 20% water glass and a flux, Coating prevents oxidation of metal by creating a protective gas shield around the electrode tip and molten pool. After solidification, the coating will form 2 slag which can be chipped off. 22.10 Flux In welding of metals, welding/filler rods supply the required metal to the joint. At high temperature, these metals form their oxides which have higher melting point than the base metal itself. These oxides have a tendency to get entrapped in the solidification metal. However, these oxides can be removed by means of agents called fluxes. A flux reacts chemically with oxides and form fusible slags at welding temperatures. This slag float to the top without interfering with the deposition of filler metal and covers the weld joint. The slag layer protects further oxidation of metal. Fluxes are available in the form of powder solutions or coatings. For welding cast iron, brass, bronze, aluminium, stainless steel ~flux is required. For welding carbon steel no flux is required as the oxide formed is lighter than the molten metal and hence floats to the top. 22.11 Gas Welding Equipment finders : ‘© Oxygen cylinders come in three sizes based on the capacity large (6.91 m’), medium (3.45 m') and small (2.26 m') © The pressure of the gas is 15.17 N mm? at 21.1°C. * Acetylene cylinder has a capacity of 8.5 m* of gas at pressures upto 1.72 N/mm’, * Acetylene cannot be stored safely below a pressure of 0.103 N/mm’. Hence it is stored in combination with acetone, It is referred to as Dissolved Acetylent gas. ‘* The cylinders are filled with a porous filler material, saturated with acetone, in which the acetylene gas is compressed. © Both the cylinders are fitted with control valves to relieve any excess pressure if the cylinder is subjected to undue heat or mechanical pressures. Welding Torch : > It consists of a series of brass tubes through which the gases are carried and finally mixed. Valves are provided for controlling the volumes of acetylene and oxygen. A copper tip from which the gas mixture is burnt is provided at the end. ‘Two types of torches are available in practice. They are mentioned below,GasWelding 337 (1) Injector type: This type is designed to use C,H, at low pressures. (ii), Medium pressure (or equal pressure) type :Here both the gases have separate control valves and hence need careful control. Comparatively disadvantageous. > Hoses : ‘Are used for carrying the individual gases to the torch, The hose needs to be stronger and rugged. Different colour hoses are used. Red colour is used for acetylene and green or black colour is used for oxygen ‘= Pressure Regulators : » These are used to (1). Reduce the cylinder pressure to working pressure 2) Maintain a steady flow of gas under varying cylinder pressures, we A regulator has (wo pressure gages one to indicate the cylinder pressure and the other to indicate_the working pressure. > Two types are available i) single stage pressure regulator ii) Two stage pressure regulator Spark lighter : is used to ignite the gaseous mixture initially, Measuring and hand Tools Measuring instruments Hand tools L. Weld gage 1. Scribe and centre punch 2. Combination square 2. hand hammer 3. Bevel protector 3. cold chisel 4, Thickness gages and micrometers 4. pliers 5. Flexible scale 5. Bleetrode holder made of Teather 6. calipers > — Blectrodes for Are Welding (1) bare electrode: limited use for welding of wrought iron and mild steel. Gi) fluxed : flux coated (iii) heavily coated: widely used (iv) Non consumable: Tungsten, carbon (¥) Consumable: mild steel copper338 Manufacturing Process ~1 QUESTIONS 1. What is the principle of gas welding ? 2. What gases are used in gas welding ? 3. Explain the chemical reaction in a gas flame 4. Explain the constructional features of a gas torch, with a neat sketch 5. Describe the welding steps using oxy-acetylene gas welding. 6. List down advantages, limitations and applications of gas welding. 7. Differentiate between left ward and right ward welding 8. Differentiate between filler rod and coated electrode 9. What is the function of flux in gas welding. 10. Write a note on gas welding equipment. Objective Type Questions 22.1 Oxygen gas burns when ignited and acetylene gas supports combustion. True / False 22.2 Acetylene gas decomposes when heated. True / False 22.3. Temperature of the flame is the highest in the reducing zone ‘True / False 22.4 Neutral flame is suitable for welding all metals True / False 22.5. Ina reducing flame acetylene content will be more than the oxygen content, ‘True / False 22.6 Oxy-acetylene gas can be used for cutting copper riser. ‘True / False 22.7 Acetylene cylinder is also referred to as DA cylinder. ‘True / False 22.8 DA cylinder consists of acetylene dissoloved in acetone or else C,H, will dissociate. True / False Controlling temperature is easy in gas welding. True / False Gas welding can be used for welding thick sections True / False Right ward welding is preferred over left ward welding True / False In left ward welding oxidation of metal takes place. True / False Right ward welding gives stronger welds. True / False 22.14 Filler rods are used in arc welding, True / False 22.15 Filler rods are normally coated with flux. True / False 22.16 Carbon is a consumable type electrode. True / False 22.17 Function of a flux is to remove oxide layer from the surface of the work. ‘True / FalseGasWelding 339 22.18 A Flux reacts chemically with oxides and form fusible slags at welding temperatures, True / False 22.19 Cast Iron is easier to weld than Mild steel. True / False 22.20 Acetone can absorb about 25 times its own volume of acetylene under atmosphere pressure and form a spongy mass. True / False Answers 22.1 False 22.2 True 22.3 False 22.4 True 22.5 True 22.6 False 22.7 True 22.8 True 22.9 True 22.10. False 22.11 True 22.12 True 22.13 True 22.14 False 22.15 False 22.16 False 22.17 True 22.18 True 22.19 False 22.20 True