Oxyacetylene Welding

Introduction:
Welding is a process for joining similar metals. Welding joins
metals by melting and fusing 1, the base metals being joined
and 2, the filler metal applied. Welding employs pinpointed,
localized heat input. Most welding involves ferrous-based
metals such as steel and stainless steel. Welding covers a
temperature range of 1500 F - 3000 F (800C - 1635C).
Weld joints are usually stronger than or as strong as the base
metals being joined.
Types of Welding we practiced in Workshop
1- Oxyacetylene Welding
2- Electric Arc Welding

Oxyacetylene Welding:
The oxyacetylene welding process uses a combination
of oxygen and acetylene gas to provide a high
temperature flame. OAW is a manual process in which
the welder must personally control the torch
movement and filler rod application .The term oxy-fuel
gas welding outfit refers to all the equipment needed
to weld. Cylinders contain oxygen and acetylene gas
at extremely high pressure.
Equipment
1. Gas Cylinders
Pressure Oxygen 125 kg/cm2 Acetylene 16
kg/cm2
2. Regulators
Working pressure of oxygen 1 kg/cm2 Working
pressure of acetylene 0.15 kg/cm2 Working
pressure varies depends upon the thickness of the
work pieces welded.
3. Pressure Gauges 6. Check valve
4. Hoses 7. Non return valve
5. Welding torch
Backfire: Flame travels in backward direction because of
touching the torch with the metal. In acetylene cylinder
backfire can take up to 40 minutes.
Reasons:
1 Hot tip
2 Touching
inner core with
material
3 Personal
errors
Types of Flames:
The neutral flame is produced when the ratio of
oxygen to acetylene, in the mixture leaving the
torch, is almost exactly one-to-one. Its termed
neutral because it will usually have no chemical
effect on the metal being welded. It will not oxidize
the weld metal; it will not cause an increase in the
carbon content of the weld metal.
The excess acetylene flame as its name implies, is
created when the proportion of acetylene in the
mixture is higher than that required to produce the
neutral flame. Used on steel, it will cause an
increase in the carbon content of the weld metal.
The oxidizing flame results from burning a mixture
which contains more oxygen than required for a
neutral flame. It will oxidize or burn some of the
metal being welded.
Arc Welding

Arc welding is a method of joining metals accomplished

by applying sufficient electrical pressure to an electrode
to maintain a current path (arc) between the electrode
and the work piece. In this process, electrical energy is
changed into heat energy, bringing the metals to a
molten state; whereby they are joined. The electrode
(conductor) is either melted and added to the base metal
or remains in its solid state.

When a filler metal is required for better bonding, filling

rod (wire) is used either as outside material fed to the arc
region or as consumable welding electrode, which melts
and fills the weld pool. Chemical compositions of filler
metal is similar to that of work piece.

Arc Welding Components

1-Electrode
2-Electrode Holder
3-Electrode Cable
4-Welding Machine (AC or DC)
5-Work Cable

Principle
The intense heat needed to melt metals is created by the
electric arc (> 6500 F) .The arc forms between the
electrode and the work surface .The welder guides the
arc along the joint by moving the electrode.
Types of joints
1-Butt joint
2-Corner joint
3-Lap joint
4-Edge joint
5-Tee joint

Defects:
Common weld defects include:
i. Lack of fusion
ii. Lack of penetration or excess penetration
iii. Porosity
iv. Inclusions
v. Cracking
vi. Undercut

Safety Precautions:
Wear protective clothing to cover all exposed areas of
the body for protection sparks, hot spatter, and
radiation.

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.

Make sure there is good local exhaust ventilation to

keep the air in your breathing zone clear.

Dont weld in wet areas, wear wet or damp clothing or

weld with wet hands.

Dont weld on containers which have held combustible

materials or on drums, barrels or tanks until proper
 safety precautions have been taken to prevent
explosions.

Dont coil the electrode cable around your body.

Ground both the frame of the welding equipment and

metal being welded.

Check for leaks in gas hoses using an inert gas.

Keep a fire watch in the area during and after welding to

be sure there are no smoldering materials, hot slag or
live sparks which could start a fire.