Week 14-15 AMT 4103 Learning Module 10

PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY

Aircraft Maintenance Technology Department
Module 10 (Finals) OXY-ACETYLENE WELDING PROCESSES
AMT 4103
AIRCRAFT MECHANICAL PROCESSES
Module 10
OXY-ACETYLENE WELDING PROCESSES
Roderick C. Santiago
AMT Instructor
1
TABLE OF CONTENTS
Title Ref. no Page

Welding Characteristics and
1 and 2 5
Nomenclature
Correct Formation of Welds 1 and 2 6
Typical Causes of Improperly
1 and 2 6
Formed Weak Welds
Chemical Changed Produced by
1 and 2 7
Welding
Physical Changed Produced by
1 and 2 7
Welding
Rate of Conductivity of Metals 1 and 2 9
Effects of High Temperature on
1 and 2 10
the Strength of Metals
Oxy-acetylene Welding Equipment 1 and 2 10
Welding Techniques 1 and 2 14
Activity 15
2
TABLE OF REFERENCES
References No.
Jepessen A and P Technician Textbook, Airframe Handbook, Jepessen
Sanderson Incorporated 1
Aviation Maintenance Technician Handbook – General (2018), US Department of

Transportation, Federal Aviation Administration 2
TIMEFRAME:
You should be able to complete this module including all the self-assessments, research works, assignments,
and other performance tasks within 3 hours.
3
Residential Learning Outcome
Course Learning Outcomes [CLO]
Module Learning Outcomes [MLO]

CLO 8. Inspect and check welds.
Topic Learning Outcomes [TLO]
CLO 10. Apply knowledge, skills,
and competence in every aspect MLO 1. The students are able to
of mechanical repair, inspection, discuss accurately the welding
maintenance and safety characteristics and nomenclature
concerns. relative to the operation of oxy- TLO 1. Explain the Welding
acetylene welding equipment Characteristics and
CLO 11. Discusses their future
role as aircraft mechanic and to MLO 2. The students are able to Nomenclature
have continuous interest for discuss accurately the safety TLO 2. Discuss the Oxy-acetylene
safety awareness purposes and to explain clearly Welding Equipment
the different welding techniques
. TLO 3. Discuss the different
Welding Techniques for Safety.
4
Welding Characteristics and Nomenclature
To make a proper weld it is necessary to identify the characteristics of a correct weld. The technician should
also be aware of the changes in material characteristics that may take place as a result of the welding
operation.
Parts of a Weld:
In the Welding Operation, there are four (4) parts of a weld such as the Face, Root, Throat and the
Reinforcement .
a. Face is the exposed surface of the weld.
b. Root is the zone at the bottom, or base, of the weld; in other words, it is the depth that fusion
penetrates into the base metal at the joint.
c. Throat is the distance through the center of the weld from the root to the face.
d. The reinforcement is the quantity of weld metal added above the surface of the base metal (the metal in
the parts being joined) to give the weld a greater thickness in cross section.
NOMENCLATURE OF A WELD
Proportions of a Weld:
The three (3) most important proportions of a weld are the Depth of Penetration, Width of the Bead and the
Height of the Reinforcement
a. Depth of penetration which should be at least one-fourth the thickness of the base metal
b. Width of the bead which should be between two and three times as great as the thickness of the base
metal
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c. Height of the reinforcement which should be not less than one-half the thickness of the base metal.
Note that these dimensions should be considered minimums and are less than the recommended
values.
• The butt weld has a bead that is three (3) to five (5) times the thickness of the base metal.
• In attaching an aircraft fitting by means of a lap weld, the width of the fillet bead is 1.5 times the thickness
of the upper sheet.
• In making a tee joint, the weld bead has a thickness through the throat that equals the thickness of the
vertical member.
• The penetration of the weld into the sides of the joint is one- fourth the thickness of the base metal, and the
height of the reinforcement meets the requirements previously given.
Correct Formation of a Weld:
A weld must be formed correctly to provide strength and to resist fatigue in a joint. If it is not made properly, the
weld may have less than fifty (50) percent of the strength for which the joint was designed.
Stated below are the typical causes of improperly formed weak welds. These incorrect conditions result from
inexperience, poor technique, or carelessness.
a. Undercutting of the base metal at the toe of the weld

b. Not enough penetration
c. Poor fusion of the weld metal with the base metal
d. Trapped oxides, slag, or gas pockets in the weld
e. Overheating of the weld
f. Overlap of the weld metal on the base metal
Typical Causes of Improperly Formed Weak Welds:
1. Undercutting of the base metal at the toe of the weld

2. Not enough penetration
3. Poor fusion of the weld metal with the base metal
4. Trapped oxides, slag, or gas pockets in the weld
5. Overheating of the weld
6. Overlap of the weld metal on the base metal
7. These incorrect conditions result from inexperience, poor technique, or carelessness.
8. Figure 30 shows a large number of faults commonly found in the weld-metal formation of various joints.
9. Any weld that has an appearance similar to one of the drawings in this illustration should be rejected.
6
COMMON FAULTS IN WELDING
Chemical Changes Produced by Welding:
1. A chemical change occurs when a substance is added or taken from a metal.
2. The heat of a welding process will cause the loss of one or more of the chemical constituents of a piece
of metal if the heat remains on the metal for any length of time; this loss usually will result in a reduction
of such physical properties of the metal as tensile strength, ductility and yield point.
3. Also, if some element is added to the metal during the welding process or if there is some material
change in one or more of the chemical constituents, the change will usually lower the strength of the
metal.
Physical Changes Produced by Welding:
1. A physical change is a change of any kind that takes place without affecting the chemical structure of a
metal.
2. Some of the physical changes most important in welding are changes in the melting point, heat
conductivity, and rate of expansion and contraction.
3. The melting point is the degree of temperature at which a solid substance becomes liquid.
4. Pure metals have a melting point, but alloys have a melting range.
5. Welders should know the approximate melting points of the various metals with which they work
because they must often weld together metals that have a widely different melting points.
6. If a metal includes an alloy element, the melting point is lowered; hence the melting points given in
tables for alloyed metals vary according to the proportion of alloying elements present and should be
considered with this fact in mind.
7
7. Some physical change takes place in the materials being welded because the application of heat during
the welding process results in expansion and contraction of the materials.
8. The technician should keep in mind the difference between temperature and heat.
9. Put simply, heat is the quantity of a temperature that is available.
10. Heat is measured in British Thermal Units (BTUs), whereas temperature is measured in degrees.
11. Expansion is an increase in the dimensions such as length, width, thickness of a substance under the
action of heat.
12. If a metal structure is unevenly heated, there will be an uneven expansion, and this will produce
distortion or warping and possibly breakage.
13. On the other hand, if the temperature is raised progressively throughout the whole mass of the object,
the action is uniform and there is no distortion or breakage.
14. Applying this to welding, if the heat from the welding process is concentrated at one point on a metal
object, the metal in the heated area tends to expand where the heat is applied, and the portion that
opposes this expansion may be distorted, cracked, or severely strained.
15. Contraction is the shrinking of a substance when cooled. It is the reverse of expansion.
16. Unless there is some restraint, materials contract as much when cooled as they expanded when they
were heated, assuming that the temperature is uniform throughout.
17. In a trussed frame, whether it is an airplane or a bridge, there is a restriction of the free movement of
the metal parts.
18. When such restrictions are present and the metal is malleable (capable of being worked into shape by
hammering, rolling, or pressing), warping will take place.
19. If the metal is brittle, it will usually crack.
20. If the piece of metal is “open”, that is, if no obstructions or restrictions hinder its free expansion and
contraction, there is no danger of its being damaged from expansion and contraction.
21. An example of open metal occurs in the case of an ordinary bar of metal, a length of unattached tubing,
or some similar detached piece of metal.
22. If the metal is “closed”, as in figure 31, there is danger from expansion and contraction.
23. The bar that was formerly free and unattached is now the center section in figure 31, and it is fastened
rigidly to a solid frame.
24. If the break marked with the letters A and B in figure below is welded, provision must be made for
expansion and contraction.
8
WELDING A CLOSED SECTION

REQUIRES HEATING OF THE ENTIRE CLOSED AREA
25. Since the crosswise and lengthwise members of the frame are rigid, they do not permit the ends of the
bar in the center to expand; hence, the only place where expansion can take place while the metal is
heated during the welding process is at the point of the weld.
26. When this portion begins to cool, the center bar contacts and shortens, but the frame in which it is
placed refuses to surrender to the inward pull of the ends of the center bar.
27. Warping occurs along the line of weld, or possibly a break occurs.
28. To avoid this damage, a trained welder heats the whole object before attempting to weld the break in
the center piece.
29. The object expands equally, pulling apart the edges of the break.
30. The welder makes the weld and allows the object to cool.
31. It all cools to the same extent, contacts equally, and suffers neither warpage nor breakage. Figure
below shows examples of shrinkage in welded metal objects.
SHRINKAGE OF METAL CAUSED BY WELDING
Rate of Conductivity of a Metal:
1. Conductivity is the physical property of a metal that permits the transmission of either an electric
current, called electrical conductivity, or heat, called thermal conductivity, through its mass.
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2. The rate of conductivity is the speed at which a metal body will transmit either an electric current or heat
through its mass.
3. The rate of conductivity varies among metals.
4. Radiation (heat loss) influences both the rate of heat conductivity and the area that will be affected by
heat conductivity.
5. Thus, metals that are good heat conductors may be poor radiators, and those that are good radiators
may be poor conductors.
6. In welding, a considerable amount of heat is carried away from the point of application and is lost to the
surrounding environment.
7. For this reason, metals that have a high thermal conductivity require more heat in welding than those
with a low conductivity, other things being equal.
Effect of High Temperatures on the Strength of Metals
1. Some metals have absolutely no strength or almost no strength when they are raised to extremely high
temperatures.
2. In some cases, this temperature may be far below the melting point of the metal.
3. For example, aluminum alloys, brass, bronze, copper, cast iron, and certain alloy steels become very
brittle at high temperatures near their melting points.
4. If such metals are strained while at these high temperatures, they will break, or check, in the area that
has been heated.
5. For example, the melting point of aluminum is 1,218 degree F.
a. At 210 degree F, it has 90 percent of its maximum strength

b. At 400 degree F, it has 75 percent of its maximum strength
c. At 750 degree F, it has 50 percent of its maximum strength
d. At 850 degree F, it has 20 percent of its maximum strength
e. At 930 degree F, it is still far below the melting point of aluminum
Oxy-acetylene Welding Equipment:
Oxyacetylene welding equipment may be either Portable Welding Equipment or a Stationary Welding
Equipment.
A portable apparatus can be fastened on a hand truck or cart and pushed around from job to job. It consists of
the following :
a. One Cylinder containing Oxygen

b. One Cylinder containing Acetylene
c. Acetylene and Oxygen Pressure Regulators
d. Complete with Pressure Gauges and Connections
10
e. Welding Torch with a mixing head, tips, and connections

f. Two Lengths of Colored Hose
g. Adapter connections for the Torch and Regulators
h. Special Wrench
i. Pair of Welding Goggles
j. Safety Flint and File Gas Lighter
k. Fire Extinguisher
A PORTABLE WELDING OUTFIT
• Stationary equipment is used where several welding stations are located close to each other and the
stations can be supplied with gases through a manifold system.
• The oxygen and acetylene cylinders, located in areas separate from each other safety, feed into the
appropriate manifold through a master regulator.
• The master regulator sets the maximum pressure for the manifold.
• Each work station has a line regulator so that the welder can set the pressure as necessary for the
particular task.
• In some shops, the acetylene does not come from cylinders. Instead, it is piped directly from an acetylene
generator, an apparatus used for producing acetylene gas by the reaction of water upon calcium carbide.
Acetylene:
Acetylene is a flammable, colorless gas with a distinctive odor that is easily detected, even when strongly
diluted with air. It is a compound of carbon and hydrogen having the chemical symbol C2H2, which means that
two atoms of carbon are combined with two atoms of hydrogen. When acetylene is mixed with air or oxygen, it
forms a highly combustible gas. It has a flame spread of 99 meters per second.
11
AN ACETYLENE CYLINDER
Oxygen:
Oxygen is a tasteless, colorless, odorless gas that forms about 23 percent by weight and about 21 percent of
volume of the atmosphere. Oxygen is an extremely active element. It combines with almost all materials under
suitable conditions, sometimes with disastrous results. For example, grease and oil are highly combustible in
presence of pure oxygen; hence it is important to avoid bringing pure oxygen into contact with oil or grease.
AN OXYGEN CYLINDER
Acetylene and Oxygen Regulators:
Acetylene and oxygen regulators are mechanical instruments used to reduce the high pressure of the gases
flowing from their containers and to supply the gases to the torch at a constant pressure and volume, as
required by the torch tip or nozzle.
12
OXYGEN PRESSURE GAUGES ON THE REGULATOR
ACETYLENE PRESSURE GAUGES ON THE REGULATOR
Welding Torches:
A welding torch is a device used to mix oxygen and acetylene together in the correct proportions and to provide
a means of directing and controlling the quality and size of the flame. The welding gases flow from the inlet
ports, past needle valves, through the tip. Needle valves are used to regulate the volumes of acetylene and
oxygen that flow into the mixing had.
Welding Hose:
A welding hose is a specially made rubber or synthetic rubber tube attached to the torch at one end and to a
pressure regulator at the other end. It is used to carry the gases from their containers to the torch. Several
techniques are used in combination to prevent the oxygen and acetylene hoses from being connected to the
wrong regulator or the wrong fitting on the torch.
The acetylene hose is usually red or maroon in color, the threads on the fittings are left-handed, the fittings
normally have a groove cut around the middle of the wrenching surface, and the word “Acetylene” may be found
on the hose or the letters ACE may be found on the fittings. The oxygen hose is normally green in color, the
fittings are right-handed with no groove on the wrenching surface, and the word “Oxygen” may be found on
some hoses or the letters OXY may be on the fittings.
Welding, or Filler, Rod:
13
The welding rod, sometimes called a filler rod, is filler metal, in wire or rod form, drawn or cast, used to supply
the additional metal required to form a joint.
Welding Safety Equipment:
Welding goggles are fitted with colored lenses to keep out heat and the ultraviolet and infrared rays produced
during welding. Clear lenses are provided in front of the colored lenses to protect the colored lenses from
damage.
The goggles should hug the face so closely that sparks and tiny pieces of hot metal cannot get inside. A pair of
welding gloves, commonly described as the gauntlet style. The material, manufacturing quality, and fit must be
such that gloves protect the hands and wrists from burns and flying sparks. They are usually made of asbestos
or of chemically treated canvas.
This device that has several names, it may be called an igniter, friction lighter, safety lighter, or spark lighter. It
is a hand-operated device used to light a gas torch safety. It consists of steel, a flint, a shield, and a spring. The
steel, usually placed in a cup-shaped shield, resembles a file and is attached to the other end of the spring.
The technician grasps the spring in one hand and compresses and releases the spring, forcing the flint to rub
across the steel, thus producing sparks that light the gas coming out
of the torch. The device is safe because it is composed of non-combustible material, the park burns only for a
fraction of a second, and the lighter is along enough to protect the welder’s hand from the flame when properly
used.
Stationary welding benches are often equipped with a pilot flame by which the welder may light the torch. If the
torch should blow out while the welder is adjusting it or while welding, it is necessary merely to pass the tip of
the torch over the pilot flame to reignite it. Never use cigarette lighters or matches. Always use the spark lighter
just describe or a pilot flame. If a cigarette lighter or matches are used, the puff of the flame from the torch may
burn the hand.
One or more portable fire extinguishers are kept at hand to be used if the flame from the welding torch, flying
sparks, or flying pieces of hot metal set fire to anything. Carbon dioxide is generally the fire extinguishing
medium used because it is effective in combining gasoline or oil fires and may be used on wood and fabric fires.
Carbon dioxide is often combined with a chemical powder, which aids in extinguishing fires.
Welding Techniques:
• Welding may be considered both a skill and an art.
• Expert welders need technical understanding of the processes with which they are working and many
hours of practice to develop the manual dexterity necessary to produce a quality weld.
• Although certificated aviation maintenance technicians are not always expected to be expert welders, they
still need to know a good weld when they see one, and they should be able to perform a satisfactory
welding job when it becomes necessary.
• Furthermore, they should know their own abilities and whether a welding specialist should be called in to
do a particular repair job.
Techniques in Holding the Torch:

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• To hold the torch when welding light-gauge metal, the torch is held as one might hold a pencil.
• The hose drops over the outside of the wrist, and the torch is held as though the welder were trying to write
on the metal.
• On holding the torch for welding heavier work, the torch is held as one would hold a hammer
• The fingers are curled underneath and the torch balanced easily in the hand so that there is no strain on
the muscles of the hand.
• A good way to describe the grip of the torch is to say that it should be held like a bird, tightly enough so
that it cannot get away but loosely enough so it will not be crushed.
Summing up:
This module has dealt with the oxy-acetylene welding processes. These include the welding characteristics and
nomenclature, correct formation of weld, typical causes of improperly formed weak weld, chemical changed
produced by welding, physical changed produced by welding, rate of conductivity of metals, effects of high
temperature on strength of metal, the familiarization on the oxy-acetylene welding equipment, and the different
welding techniques during the process of welding operations.
Enrichment Activity
Why is it necessary for Aviation Maintenance Technicians to know the welding job in aircraft maintenance
work? (30 minutes)
Honesty Clause:
“I affirm that I will not give or receive any unauthorized help on this module activities, and that all work will be
my own understanding in each topic content and discussion”
______________________
Signature over Printed Name
Rubrics for Essay:

Needs
Excellent Very Satisfactory Satisfactory Unsatisfactory
Category Improvement Total
(96 – 100) (91- 95) (86 – 90) (76 – 80)
(81 – 85)
A Comprehensive grasp A thorough grasp of the A basic grasp of the Subject content show Major issues with
of the subject matter is subject matter is subject matter is some articulating the key
demonstrated including demonstrated demonstrated misunderstanding of elements of the
Subject Content an in-depth major points, is issues
understanding of the missing elements.
relevant concepts,
theories and related
issues of the topic
15
An awareness of An awareness of differing Asserts viewpoints without The topic is lack of The topic is
differing viewpoints is viewpoints is demonstrated acknowledging alternative supporting ideas unsupported and it
Awareness of demonstrated and a and an assessment of viewpoints is not completely
the topic rigorous assessment of these attempted where articulated
the undertaken where relevant
relevant
An ability to think The answers go beyond Accurate information The information Answers do not
critically is description to interpretation, incorporating relevant needs more align with the
demonstrated in the analysis and evaluation answers is conveyed supporting details description to
Critical Thinking
problem of the relevant that is relevant to the interpretation,
information topic analysis and
evaluation
Total: __________________________
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PHILIPPINE STATE COLLEGE OF AERONAUTICS

INSTITUTE OF ENGINEERING AND TECHNOLOGY

Title Ref. no Page

Aviation Maintenance Technician Handbook – General (2018), US Department of

Residential Learning Outcome

Course Learning Outcomes [CLO]

Module Learning Outcomes [MLO]

Welding Characteristics and Nomenclature

a. Face is the exposed surface of the weld.

Correct Formation of a Weld:

a. Undercutting of the base metal at the toe of the weld

Typical Causes of Improperly Formed Weak Welds:

1. Undercutting of the base metal at the toe of the weld

COMMON FAULTS IN WELDING

Chemical Changes Produced by Welding:

1. A chemical change occurs when a substance is added or taken from a metal.

Physical Changes Produced by Welding:

9. Put simply, heat is the quantity of a temperature that is available.

19. If the metal is brittle, it will usually crack.

WELDING A CLOSED SECTION

SHRINKAGE OF METAL CAUSED BY WELDING

Rate of Conductivity of a Metal:

3. The rate of conductivity varies among metals.

Effect of High Temperatures on the Strength of Metals

5. For example, the melting point of aluminum is 1,218 degree F.

a. At 210 degree F, it has 90 percent of its maximum strength

Oxy-acetylene Welding Equipment:

a. One Cylinder containing Oxygen

e. Welding Torch with a mixing head, tips, and connections

A PORTABLE WELDING OUTFIT

Acetylene and Oxygen Regulators:

OXYGEN PRESSURE GAUGES ON THE REGULATOR

ACETYLENE PRESSURE GAUGES ON THE REGULATOR

Welding, or Filler, Rod:

Welding Safety Equipment:

• Welding may be considered both a skill and an art.

Techniques in Holding the Torch:

Rubrics for Essay:

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