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GAS WELDING PROCESS

Gas welding is a fusion welding process. It joins metals, using the heat of
combustion of an oxygen/air and fuel gas (i.e. acetylene, hydrogen,
propane or butane) mixture. The intense heat (flame) thus produced melts
and fuses together the edges of the parts to be welded, generally with the
addition of a filler metal.

When acetylene is mixed with oxygen in correct proportions in the welding


torch and ignited, the flame resulting at the tip of the torch is sufficiently
hot to melt and join the parent metal.

The oxyacetylene flame reaches a temperature of about 3200°C and thus


can melt all commercial metals which, during welding, actually flow
together to form a complete bond.

A filler metal rod is generally added to the molten metal pool to build up
the seam slightly for greater strength. Oxyacetylene welding does not
require the components to be forced together under pressure until the weld
forms and solidifies.

Types of Welding Flames –


Open the acetylene control valve of the welding torch and after the system
has been flushed clean of air the gas is ignited.
At this stage, enough of oxygen is drawn in from the atmosphere to burn
acetylene partially. The acetylene control valve is then adjusted until the
flame ceases to smoke.

The oxygen control valve of the welding torch is then opened in order to
adjust the proportions in which acetylene and oxygen are required to mix
and burn. This results in three distinct types of flames as discussed under.

Types of Flames
1. Neutral Flame (Acetylene oxygen in equal proportions)
2. Oxidising Flame (Excess of oxygen)
3. Reducing Flame (Excess of acetylene)

In oxyacetylene welding, flame is the most important tool. All the welding
equipment simply serves to maintain and control the flame.
The correct type of flame is essential for the production of satisfactory
welds.
The flame must be of the proper size, shape and condition in order to
operate with maximum efficiency.

Neutral Flame
A neutral flame is produced when approximately equal volumes of oxygen
and acetylene are mixed in the welding torch and burnt at the torch tip.
(More accurately the oxygen-to-acetylene ratio is 1.1 to 1). The temperature
of the neutral flame is of the order of about 5900ºF (326ºC)
The flame has a nicely defined inner cone* which is light blue in colour.

It is surrounded by an outer flame envelope, produced by the combination


of oxygen in the air and superheated carbon monoxide and hydrogen gases
from the inner cone.

This envelope is usually a much darker blue than the inner cone.
A neutral flame is named so because it effects no chemical change in the
molten metal and therefore will not oxidize or carburize the metal.

The neutral flame is commonly used for the welding of:


(i) Mild steel
(ii) Stainless steel
(iii) Cast Iron
(iv) Copper
(v) Aluminium

Oxidising Flame -
If, after the neutral flame has been established, the supply of oxygen is
further increased, the result will be an oxidising flame.

An oxidising flame can be recognized by the small white cone which is


shorter, much bluer in colour and more pointed than that of the neutral
flame.

The outer flame envelope is much shorter and tends to fan out at the end
on the other hand the neutral and carburizing envelopes tend to come to a
sharp point.

An oxidising flame burns with a decided loud roar. An oxidising flame


tends to be hotter than the neutral flame.
This is because of excess oxygen and which causes the temperature to rise
as high as 6300°F.

The high temperature of an oxidizing flame (O2: C2H2 = 1.5: 1) would be an


advantage if it were not for the fact that the excess oxygen, especially at
high temperatures, tends to combine with many metals to form hard,
brittle, low strength oxides.

Moreover, an excess of oxygen causes the weld bead and the surrounding
area to have a scummy or dirty appearance.

For these reasons, an oxidising flame is of limited use in welding.


It is not used in the welding of steel. A slightly oxidising flame is helpful
when welding most
(i) Copper base metals
(ii) Zinc base metals,

Reducing Flame –
If the volume of oxygen supplied to the neutral flame is reduced, the
resulting flame will be a carburising or reducing flame, i.e. rich in
acetylene.

A reducing flame can be recognized by acetylene feather which exists


between the inner cone and the outer envelope.

The outer flame envelope is longer than that of the neutral flame and is
usually much brighter in colour.

A reducing flame does not completely, consume the available carbon;


therefore, its burning temperature is lower and the left over carbon is
forced into the molten metal.

With iron and steel it produces very hard, brittle substance known as iron
carbide.

This chemical change makes the metal unfit for many applications in which
the weld may need to be bent or stretched.
Metals that tend to absorb carbon should not be welded with reducing
flame.

A reducing flame has an approximate temperature of 5500°F (3038°C). A


reducing flame may be distinguished from a carburizing flame by the fact
that a carburizing flame contains more acetylene than a reducing flame.

A carburizing flame is used in the welding of lead and for carburizing


(surface hardening) purposes.
Leftward Technique –
The welder holds welding torch in his right hand and filler rod in the left
hand.
The welding flame is directed away from the finished weld, i.e., towards
the unwelded part of the joint.
Filler rod, when used, is directed towards the welded part of the joint.

Fig. Leftward technique

The weld is commenced on the right hand side of the seam, working
towards the left hand side.

The blowpipe or welding torch is given small sideways movements, while


the filler rod is moved steadily across the seam.

The filler rod is added using a backward and forward movement of the
rod, allowing the flame to melt the bottom edges of the plate just ahead of
the weld pool.
Since the flame is pointed in the direction of the welding, it preheats the
edges of the joint.

Good control and a neat appearance are characteristics of the leftward


method.

Leftward technique is usually used on relatively thin metals, i.e., having


thicknesses less than 5 mm.

When work piece thickness is over 3 mm, it is necessary to bevel the plate
edges to produce a V-joint so that good root fusion may be achieved.

The included angle of V-joint is 80-90°.

This large volume weld is uneconomical in terms of time, weld metal


deposited and quantity of gases used and may also over distort the
weldment when welding thick materials.
Data for Leftward Welding –
Plate Edge Distance Filler rod Power of Rate of
thickness Preparation between diameter, blowpipe welding
mm edges, mm litre/hr (Gas metres/hr
mm consumption)

0.8 Square -- 1.6 22 - 44 6 - 7.6

1.6 Square 1.6 1.6 44 - 66 7.6 - 9

2.4 Square 2.4 1.6 66 - 107 6 - 7.6

3.2 Square 3.2 3.2 107 - 153 5.4 - 6

4.0 80°V 3.2 3.2 153 - 214 4.6 - 5.4

5.0 80°V 3.2 3.2 214 - 283 3.6 - 4.6


Rightward Technique –
Here again the welding torch is held in the right hand of the welder and
the filler wire in the left.

Welding begins at the left hand end of the joint and proceeds towards the
right, hence the name rightward technique.

Fig. Rightward technique

The direction of welding is opposite to that when employing the leftward


technique.

The torch flame in rightward technique is directed towards the completed


weld and the filler rod remains between the flame and the completed weld
section, since the flame is constantly directed on the edges of the V ahead
of the weld puddle, no sidewise motion of the welding torch is necessary.

As a result a narrower V -groove (30° bevel or 60° included angle) can be


utilized than in leftward welding.
This provides a greater control and reduced welding costs.

During welding, the filler rod may be moved in circles (within the puddle)
or semicircles (back and forth around the puddle.)

In rightward welding, the weld puddle is less fluid and this result in a
slightly different appearance of the weld surface.

The ripples are heavier and spaced further apart.

The rightward technique is one used on heavier or thicker (above 5 mm)


base metals, because in this technique the heat is concentrated into the
metal.

Welds with penetrations of approximately 12 mm can be achieved in a


single pass.

Rightward technique has got certain. Advantages over the left ward one, as
listed below:
i) Up to 8.2 mm plate thickness no bevel is necessary. This saves the cost of
preparation and reduces the consumption of filler rod.

(ii) For welding bigger thicknesses, where beveling of plate edges becomes
necessary, the included angle of V need be only 60°, which requires less
filler metal against 80°V preparation used in leftward welding technique.
(iii) The welder's view of the weld pool and the sides and bottom of the V
groove is unobstructed. This results in better control and higher welding
speeds.
(iv) The smaller total volume of deposited metal, as compared to leftward
welding, reduces shrinkage and distortion.

(v) The weld quality is better than that obtained with the leftward
technique.

(vi) Owing to less consumption of the filler metal,

Data for Rightward Welding -


Plate Edge Distance Filler rod Power of Rate of
thickness Preparation between diameter, blowpipe welding
mm edges, mm litre/hr (Gas metres/hr
mm consumption)

5.0 Square 2.4 2.4 370 - 520 3.6 - 4.6

6.5 Square 3.2 3.2 520 - 570 3.0 - 3.6

8.2 Square 4.0 4.0 710 - 860 2.1 - 2.4

10.0 60°V 3.2 5.0 1000 - 1300 1.8 - 2.1

13.0 60°V 3.2 6.5 1300 - 1400 1.3 - 1.5

16.2 60°V 3.2 6.5 1600 - 1700 1.1 - 1.3

19.0 60°V (Top) 4.0 6.5 1700 - 2000 0.9 - 1.0


80°V (Bottom)

25.0 60°V (Top) 4.0 6.5 2000 - 2500 0.6- 0.7


80°V (Bottom)

Gas Welding Equipment -


The basic equipments used to carry out gas welding are:
1. Oxygen gas cylinder.
2. Acetylene gas cylinder.
3. Oxygen pressure regulator.
4. Acetylene pressure regulator.
5. Oxygen gas hose (Blue).
6. Acetylene gas hose (Red).
7. Welding torch or blow pipe with a set of nozzles and gas lighter
8. Trolleys for the transportation of oxygen and acetylene cylinders
9. A set of keys and spanners.
10. Filler rods and fluxes.
11. Protective clothing for the welder (e.g., asbestos apron, gloves, goggles,
etc.)
Manifold System for Gas Welding -
In an industry where considerable gas welding is done and at several
places or where rate of gas consumption is high, it is much advantageous
to use a manifold system.

In a manifold system, instead of having gas cylinders at each place of work,


they are assembled at one centralized position in specially designed racks
and connected by a manifold.

The gas is then distributed by means of a pipeline to different workplaces.

The manifold distributes welding gases at a reduced pressure.

There are separate manifolds for oxygen and acetylene gas supplies.
A manifold system for acetylene.

An oxygen manifold system differs from it in the following ways:


(i) There is no anti flashback device in an oxygen manifold system.
(ii) Oxygen supply line is a copper pipe whereas acetylene supply line is a
steel pipe.
(iii) An oxygen pressure regulator is used in an oxygen manifold system.

Advantages of Using Manifolds -

1. Since gas cylinders have not been scattered throughout the work area,
rather, they have been kept at a central place:
(a) The possibility of accidents is reduced.
(b) More space is available at each workplace.
2. In case of fire, one can easily reach the cylinders.
3. There is more effective use of gases.
4. Cylinders are transported by less distance.
5. There is no replacement of cylinders inside the workshop.

Welding Torch
Oxygen and the fuel gas having been reduced in pressure by the gas
regulators are fed through suitable hoses to a welding torch which mixes
and controls the flow of gases to the welding nozzle or tip where the gas
mixture is burnt to produce a flame for carrying out gas welding operation.

There are two types of welding torches, namely:


(i) High pressure (or equal pressure) type.
(ii) Low pressure (or injector) type.

High pressure blowpipes or torches are used with (dissolved) acetylene


stored in cylinders at a pressure of 8 bar. Low pressure blowpipes are used
with acetylene obtained from an acetylene generator at a pressure of 200
mm head of water (approximately 0.02 bar).

A) Working of a low pressure blowpipe:


It is termed as a low pressure blowpipe because it can be operated at
low acetylene pressures; it is frequently used with acetylene
generators. As acetylene is of low pressure, it is necessary to use
oxygen at a high pressure (2.5 bar).

The oxygen enters the mixing chamber through a passage located in


the centre of the torch.

The oxygen passage is surrounded by the one carrying the acetylene.


The high pressure oxygen passes through a small opening in the
injector nozzle, enters the mixing chamber and pulls (or draws) the
acetylene in after it.

An advantage of low pressure torch is that small fluctuations in the


oxygen supplied to it will produce a corresponding change in the
amount of acetylene drawn, thereby making the proportions of the
two gases constant while the torch is in operation.

B) Working of a high pressure blowpipe:

In this type of blowpipe both the oxygen and acetylene are fed to the
blow pipe at equal pressures and the gases are mixed in a mixing
chamber prior to being fed to the nozzle tip.

The equal pressure or high pressure type of blowpipe is the one most
generally used because
(i) It is lighter and simpler.
(ii) It does not need an injector.
(iii) In operation, it is less troblesome since it does not suffer from
backfires to the same extent.

To change the power of the welding torch, it is only necessary to


change the nozzle tip (size) and increase or decrease the gas
pressures appropriately.

Advantages of Gas Welding -

1. It is probably the most versatile process. It can be applied to a wide


variety of manufacturing and maintenance situations.

2. Welder has considerable control over the temperature of the metal in the
weld zone. When the rate of heat input from the flame is properly
coordinated with the speed of welding, the size, viscosity and surface
tension of the weld puddle can be controlled, permitting the pressure of the
flame to be used to aid in positioning and shaping the weld.

3. The rate of heating and cooling is relatively slow. In some cases, this is
an advantage.

4. Since the sources of heat and of filler metal are separate, the welder has
control over filler metal deposition rates. Heat can be applied preferentially
to the base metal or the filler metal.
5. The equipment is versatile, low cost, self sufficient and usually portable.
Besides gas welding, the equipment can be used for preheating, post
heating, braze welding, torch brazing and it is readily converted to oxygen
cutting.

6. The cost and maintenance of the welding equipment is low when


compared to that of some other welding processes.

Disadvantages of Gas Welding -


1. Heavy sections cannot be joined economically.
2. Flame temperature is less than the temperature of the arc.
3. Fluxes used in certain welding and brazing operations produce fumes
that are irritating to the eyes, nose, throat and lungs.
4. Refractory metals (e.g., tungsten, molybdenum, tantalum, etc.) and
reactive metals (e.g., titanium and zirconium) cannot be gas welded.
5. Gas flame takes a long time to heat up the metal than an arc.
6. Prolonged heating of the joint in gas welding results in a larger heat
affected area. This often leads to increased grain growth, more distortion
and, in some cases, loss of corrosion resistance.
7. More safety problems are associated with the handling and storing of
gases.
8. Acetylene and oxygen gases are rather expensive.
9. Flux shielding in gas welding is not so effective as an inert gas shielding
in TIG or MIG welding.
Applications of Gas Welding -
1. For joining thin materials.
2. For joining materials in whose case excessively high temperatures or
rapid heating and cooling of the job would produce unwanted or harmful
changes in the metal.
3. For joining materials in whose case extremely high temperatures would
cause certain elements in the metal to escape into the atmosphere.
4. For joining most ferrous and nonferrous metals, e.g., carbon steels, alloy
steels, cast iron, aluminium, copper, nickel, magnesium and its alloys, etc.
5. In automotive and aircraft industries. In sheet metal fabricating plants,
etc.

Welding Filler Metal Rods –

Filter metal is the material that is added to the weld pool to assist in filling
the gap (or groove).

Filler metal forms an integral part of the weld.

Filler metal is usually available in rod form. These rods are called Filler
Rods.

Filler rods have the same or nearly the same chemical composition as the
base metal.
Welding filler rods are available in a variety of compositions (for welding
different materials) and sizes.

Welding Fluxes –
During welding, if the metal is heated/melted in air, oxygen from the air
combines with the metal to form oxides which result in poor quality, low
strength welds or, in some cases, may even make welding impossible.

In order to avoid this difficulty, a flux is employed during welding.

A flux is a material used to prevent, dissolve or facilitate removal of oxides


and other undesirable substances.

A flux prevents the oxidation of molten metal. The flux (material) is fusible
and non metallic.

During welding, flux chemically reacts with the oxides and a slag is formed
that floats to and covers the top of the molten puddle of metal and thus
helps keep out atmospheric oxygen and other gases.

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