KM 104

GAS WELDING REPORT

[Nama] | 01DKP13F1030 | 18 Oktober 2013

DEFINITION OF WELDING
Welding is a materials joining process which produces coalescence of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material. Welding is used for making permanent joints. It is used in the manufacture of automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building.

DEFINITION OF GAS WELDING

It is a fusion welding in which strong gas flame is used to generate heat and raise temperature of metal pieces localized at the place where joint is to be made. In this welding metal pieces to be joined are heated. The metal thus melted starts flowing along the edges where joint is to be made. A filler metal may also be added to the flowing molten metal to fill up the cavity at the edges. The cavity filed with molten metal is allowed to solidify to get the strong joint. Different combinations of gases can be used to obtain a heating flame. The popular gas combinations are oxyhydrogen mixture, oxygen-acetylene, and etc. different mixing proportion of two gases in a mixture can generate different types of flames with different characteristics.

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GAS WELDING EQUIPMENT

GAS WELDING SAFETY EQUIPMENT

GOOGLE

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APRON

GLOVE

SAFETY SHOES

GAS WELDING EQUIPMENT

TORCH

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HOSE

FLASHBACK ARRESTOR

OXYGEN PRESSURE REGULATOR

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ACYTELENE PRESSURE REGULATOR

CYLINDER

SPARK LIGHTER

FILLER ROD

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PLIERS

WIRE BRUSH

TYPE AND PROPERTIES OF FLAMES, WORKING FLAME

There are three basic flame types:

i. ii. iii.

Neutral (or balanced) Reducing or carburizing (excess acetylene) Oxidizing (excess oxygen)

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i.

Natural flame: which has one-to-one ratio of acetylene and oxygen

Obtains additional oxygen from the air and provides complete combustion The neutral flame has a clear or luminous cone indicating Used for most welding operations such as steel, cast iron, cooper, aluminium and for preheating during cutting operations. Temperature at the inner cone tip is approximately 5850F (3232C)

ii.

Oxidizing flame: Which has an excess of oxygen. Has a shorter envelope and a small pointed whited cone The reduction in length of the inner cone is a measure of excess oxygen This flame tends to oxidize the weld metal The temperature of this flame is approximately 6300F (3482C) at the inner cone tip

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 An oxidizing flame should not be used for welding steel because the deposited metal will be porous, oxidized, and brittle. A slightly oxidizing flame is used weld brass and bronze

iii.

Carburizing flame: which has excess acetylene The inner cone has a feathery edge extending beyond it If the acetylene feather is twice as long as the inner cone it is known as a 2x flame, which is a way of expressing the amount of excess acetylene The carburizing flame may add carbon to the weld metal It has a temperature of approximately 5700F (3149C) at the inner cone tips A carburizing flame is advantageous to weld monel metal (certain alloy steels and hard facing such as nonferrous alloys as nickel.

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WELDING OPERATION

I. II.
III.

PRESSURE SETTING LIGHTTING UP CLOSING DOWN

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SAFETY PRECAUTIONS

GENERAL SAFETY PRACTICES

Some hazards are common to both electric arc and oxygen-fuel gas welding. If you work with or near a welding operation, the following general precautions should help you to work more safely. Weld only in designated areas Only operate welding equipment you have been trained to use Know what the substance is thats being welded and any coating on it Wear protective clothing to cover all exposed areas of the body for protection sparks, hot spatter, and radiation Protective clothing should be dry and free of holes, grease, oil, and other substance which may burn Wear flameproof gauntlet gloves , a leather apron, and high-top shoes to provide good protection against sparks and spatter Wear specifically designed, leak-proof helmets equipped with filter plates to protect against ultraviolet, infrared, and visible radiation. Never look at a flash, even for an instant Keep your head away from the plume by staying back and to the side of the work. Use your helmet and head position to minimize fume inhalation in your breathing zone Make sure there is good local exhaust ventilation to keep the air in your breathing zone clear

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 Don weld in a confined space without adequate ventilation and a NIOSH-approved respirator Dont weld in wet areas, wear wet or damp clothing or weld with wet hands Dont coil the electrode cable around your body Keep a fire watch in the area during and after welding to be sure there are no smouldering materials, hot slag or live sparks which could start a fire Locate the nearest fire extinguisher before welding Provide enough ventilation wherever gas welding, cutting, and heating operations are performed. Proper ventilation will protect the operator from the evolving noxious fumes and gases.

SAFETY PRACTICES OF GAS WELDING

GENERAL SAFETY PRACTICE

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Some hazards are common to both electric arc and oxygen-fuel gas welding. If you work with or near a welding operation, the following general precautions should help you to work more safely. Weld only in designated areas Only operate welding equipment you have been trained to use Know what the substance is thats being welded and any coating on it Wear protective clothing to cover all exposed areas of the body for protection sparks, hot spatter, and radiation Protective clothing should be dry and free of holes, grease, oil, and other substance which may burn Wear flameproof gauntlet gloves , a leather apron, and hightop shoes to provide good protection against sparks and spatter Wear specifically designed, leak-proof helmets equipped with filter plates to protect against ultraviolet, infared, and visible radiation. Never look at a flash, even for an instant Keep your head away from the plume by staying back and to the side of the work. Use your helmet and head position to minimize fume inhalation in your breathing zone Make sure there is good local exhaust ventilation to keep the air in your breathing zone clear Don weld in a confined space without adequate ventilation and a NIOSH-approved respirator

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 Dont weld in wet areas, wear wet or damp clothing or weld with wet hands Dont coil the electrode cable around your body Keep a fire watch in the area during and after welding to be sure there are no smouldering materials, hot slag or live sparks which could start a fire Locate the nearest fire extinguisher before welding Provide enough ventilation wherever gas welding, cutting, and heating operations are performed. Proper ventilation will protect the operator from the evolving noxious fumes and gases.

SAFETY PRACTICE OF GAS WELDING WORK

Use correct shaded lens when welding. Wear heat-resistant, non-flammable gloves.

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 Keep area and clothes free from grease or oil. Do not oil or grease cylinder screws. Report defective material or tools to instructor Welding and cutting should be done in well ventilated areas Use soap and water to check for gas leaks

PERSONAL PROTECTIVE EQUIPMENT

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GOGGLES

APRON

GLOVES

HOUSEKEEPING WORKS

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A good housekeeping program plans and manages the orderly storage and movement of materials from point of entry to exit. It includes a material flow plan to ensure minimal handling. The plan also ensures that work areas are not used as storage areas by having workers move materials to and from work areas as needed. Part of the plan could include investing in extra bins and more frequent disposal. The costs of this investment could be offset by the elimination of repeated handling of the same material and more effective use of the workers' time. Often, ineffective or insufficient storage planning results in materials being handled and stored in hazardous ways. Knowing the plant layout and the movement of materials throughout the workplace can help plan work procedures. Worker training is an essential part of any good housekeeping program. Workers need to know how to work safely with the products they use. They also need to know how to protect other workers such as by posting signs (e.g., "Wet - Slippery Floor") and reporting any unusual conditions.

Housekeeping order is "maintained" not "achieved." Cleaning and organization must be done regularly, not just at the end of the shift. Integrating housekeeping into jobs can help ensure this is done. A good
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housekeeping program identifies and assigns responsibilities for the following: clean up during the shift Day-to-day cleanup Waste disposal Removal of unused materials Inspection to ensure cleanup is complete Do not forget out-of-the-way places such as shelves, basements, sheds, and boiler rooms that would otherwise be overlooked. The orderly arrangement of operations, tools, equipment and supplies is an important part of a good housekeeping program. The final addition to any housekeeping program is inspection. It is the only way to check for deficiencies in the program so that changes can be made. The documents on workplace inspection checklists provide a general guide and examples of checklists for inspecting offices and manufacturing facilities.

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