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Propane (C3H) is supplied in a liquid form under positive pressure, which varies with temperature. Most
oxyfuel cutting torches can use LP gas, but special hoses and cutting tips are required. Propane is readily
available in most areas. For the most effective and efficient use of propane as a cutting fuel, specially
designed and manufactured torches should be purchased. Due to cost, propane cutting is heavily used in the
metal recycling industry.
Propylene (C3H6) is a fuel gas that has been used for approximately 30 years. It is stable in both liquid and
gas states, economical, produces little slag, and has a high heat value. This heat value is due to the fact that
the molecules in propylene are united in a double carbon bond. Breaking down this double bond produces
more heat. Propylene does not have the withdrawal pressure limitations that are necessary with acetylene.
According to MSDS information, the propylene used for oxyfuel cutting is approximately 5% propylene,
87% propane, and traces of other gasses.
Acetylene (C2H2) is the most widely used fuel gas for welding and cutting applications. It produces a clean
weld and a controllable flame. It is less stable and more expensive than other fuel gases. However, since it
performs most functions well and is widely available, it is the most commonly used fuel gas for most agricultural
mechanics laboratories and service centers.
Compressed natural gas (CH4) is adaptable for cutting, soldering, brazing, and preheating. A water seal or
blowback valve to prevent backfiring into the gas supply line must protect the natural gas source.
Physical and Chemical Properties of Oxyfuel Gasses
Factor
Specific gravity
o
Propylene
Acetylene
Propane
Natural Gas
1.49
0.906
1.52
0.62
Boiling point ( F)
-54
-8.4
-50
-161
Neutral flame
o
temperature ( F)
5340
5700
4700
4500
Heat emission of
primary flame
3
(BTU per ft )
434
507
255
12
Secondary flame
o
temperature ( F)
1938
963
2240
990
2372
1470
2495
1000
21,600
21,500
21,600
23,600
Cutting, heating,
stress relieving,
brazing, soldering
Cutting, heating,
stress relieving,
brazing, soldering
Cutting
Production cutting
BTU per ft
Total heating
value (BTU per lb)
Common uses
The oxyfuel flame is also used to bend, shape, preheat, stress relieve, post-heat, and temper metals.
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b.
c.
d.
e.
Attach the regulators to the cylinders so that they point toward the ceiling to prevent someone from
getting in front of the regulator.
f.
The regulators, safety check valves, and hoses should be tightened securely with a wrench.
g.
Do not use a wrench to attach the welding tip or cutting attachment to the torch.
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OXYFUEL EQUIPMENT
Oxyfuel equipment is designed with several built-in safety precautions. Oxygen hoses are usually green; fuel
gas hoses are red. All oxygen connections and cylinders have right-hand threads. All fuel gas connections and
cylinders have left-hand threads. Fuel gas fittings have a V notch cut around the outside of the connectors;
oxygen fittings and connectors are smooth.
a.
Cylinders two.
b.
Regulators two sets, two stage regulators are the safest to use.
c.
Hoses color-coded and specifically designed based on use. Type R fuel gas hoses are designed
specifically for acetylene use, while Type T hoses are approved for all fuel gasses.
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d.
Safety Check Valves two sets recommended, attach between regulators and hoses and between
hoses and torch to prevent reverse flow of the gases and flame (flashback) that could cause hose
fires, regulator ruptures, and cylinder fires.
e.
Torch handle regulated by two valves, often equipped with internal reverse flow check valves.
f.
Cutting attachment regulated by preheat oxygen control valve, operated by depressing the cutting
oxygen lever.
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g.
Cutting tips 3 to 8 preheat orifices and 1 oxygen-cutting orifice. Drill size determines tip size. The
propane tip is a 2-piece tip with at least 6 preheat orifices.
h.
Welding tip 1 orifice for gas mixture; the size is determined by drill size of orifice.
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i.
Miscellaneous tip cleaner, spark lighter, adjustable locking pliers, wire brushes.
j.
-7-
Keep oil and grease away from all parts of the welding and cutting apparatus.
b.
c.
Face the regulator gauges up toward the ceiling, making it impossible to stand in front of them.
d.
Store and use oxyfuel units in well ventilated areas adequately separated from other activities.
e.
Acetylene pressure in the lines should NEVER exceed 15 pounds per square inch.
f.
Open the acetylene cylinder valve 1/4 to 1/2 turns; if it is the wheel type, open all the way.
g.
Use an approved spark lighter to light the torch; never use matches or cigarette lighters.
h.
NEVER use oxygen to operate pneumatic tools, blow out lines, inflate tires, or dust off clothing.
i.
Never hang clothing on cylinders, running the risk of saturating them with oxygen and acetylene.
j.
k.
Slowly open the oxygen cylinder valve to prevent a sudden surge of pressure.
l.
Release or loosen the regulator adjusting screw before opening a cylinder valve.
m.
n.
o.
Repair hoses with proper hose splices, not friction tape. NEVER use a leaking hose.
p.
q.
If valves on cylinders are faulty or too tight, notify the supplier; undue force would be dangerous.
r.
s.
t.
u.
v.
w.
x.
y.
Oxygen and fuel gas cylinders (either full or empty) MUST be stored separately in accordance with
safety and fire codes.
-8-
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Turn off acetylene valve on torch butt (the flame goes out) NEVER turn off oxygen first.
2.
3.
4.
Bleed acetylene hose by opening acetylene torch valve (both gauges drop to 0), close valve.
5.
6.
7.
Bleed oxygen hose by opening oxygen torch valve (both gauges drop to 0), close valve.
8.
9.
Recheck valves for closure, roll up hoses. If rig is not to be used for some time, remove the regulators
and put the safety caps back on the cylinders.
10. NEVER leave equipment under pressure 24 hours a day, close equipment daily.
CUTTING METALS
The metal to be cut should be clean, marked with a punch or soapstone, and placed in a suitable position for
cutting. To prevent damage where hot metal falls, do not cut over a concrete floor. Use a container or
special cutting table device to catch the molten metal. Hot metal can also damage hoses and cause fires.
Oxyfuel cutting is limited to ferrous metals such as carbon steels, alloy steels, low chromium steels, and
manganese steels. Steels with a high tungsten or chromium content or stainless steel cannot be cut with
oxyfuel. Cast iron is more difficult to cut than steel; therefore, an excess fuel flame is used. More oxygen
pressure is needed due to the fact that more heat is required for cast iron. The cutting tip is held at 45
degrees to start the cut and raised to 75 degrees to make the cut.
The steps to follow in making a cut are:
1.
Hold the blowpipe perpendicular to the surface of the metal unless bevels are to be cut. Hold the
flame inner cone about 1/16 to 1/8 inch above the plate. The proper distance away from the plate will
prevent metal from sticking to the tip. Hold the tip so that two preheat holes are in line with the cut
(one leading the cut, and the other following the cut).
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2.
Hold the torch at the edge of the metal until the metal begins to melt. The top of the torch may be
slanted toward the cut and changed to a vertical position as the cut progresses.
3.
Press down slowly on the cutting oxygen lever until the cutting valve is completely open. When the
cut is through the metal, move the torch along the mark.
4.
Tilt the torch tip toward the direction of cut on thin metal. It should be held in a vertical position on
thick metal.
5.
Move the torch slowly along the surface or the oxygen stream will not pass completely through thick
metal. To restart the cut, release the cutting lever and reheat the metal again before pressing the
cutting lever. Losing the cut may cause irregular edges.
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6.
When beveling plate edges or cutting at an angle, lean the tip at the desired angle and hold the torch
parallel to the work.
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5.
Hold the blowpipe tip perpendicular to the surface until a spot on the surface begins to melt.
Raise the torch until the tip is about 1/2 inch from the surface and slowly press the lever as the torch
is raised.
Move the tip to one side of the heated area so that the slag can be blown out.
Move the inner cone within about 1/8 inch from the surface and make the cut on the inside edge of
the hole.
To facilitate the cutting of a hole in thick metal, drill a hole 1/4 in diameter or larger and start the
piercing in this hole.
The tip point can be cleaned and squared by rubbing with emery cloth, steel wool, or the file on a
tip cleaner.
Insert the correct size cleaner into each orifice. Push in and pull out; do not twist or bend the cleaner.
Open oxygen slightly during this procedure to blow out foreign particles.
Care should be taken not to damage the threads and seats of the tips.
Free the metal from oil, paint, grease, dirt, rust, and other foreign material. Heat the metal with the
torch, and then clean with a wire brush.
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b.
c.
Align the plates to be welded and tack weld them to prevent warping.
The blowpipe can be held like a hammer when standing or like a pencil when working in the sitting
position.
b.
The tip should be held at a 45-degree angle to the work surface. The welding rod should also be held
at a 45-degree angle to the surface and in line with the weld.
c.
The inner cone flame should be 1/16 to 1/8 inch above the metal.
d.
Preheating the metal is very important in making a successful weld; therefore, the flame should be
moved in the direction of the weld, and the cone should stay inside the puddle.
The most common movement pattern for fusion welding is the circular motion. The zigzag motion is best
when using a filler rod.
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When using either pattern, the torch should be held at about 45 degrees to the surface. The welding rod
should be held at 45 degrees, but slanted away from the torch tip. The rod diameter should be equal to the
thickness of the metal. The torch may be held so the tip is pointed in the direction of the weld (forehand
welding) or the tip pointed toward the weld (backhand welding).
2.
The main advantage to braze welding is that it does not require an extremely high welding temperature that
may change the malleable properties of the metal.
a.
b.
c.
d.
e.
Hardsurfacing is the application of an all alloy material to another metal for the purpose of reducing
wear. Metals subjected to abrasive wear, such as cultivator sweeps and bucket or digger teeth, can
be hardsurfaced.
2.
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(For additional information about oxyfuel cutting and welding, refer to IMS video #9784 Oxyacetylene
Welding: Safety and Introduction, #9785 Oxyacetylene Welding and Brazing, #9786 Oxyacetylene Cutting,
and #9787 Acetylene Cylinder Safety.)
(For oxyfuel cutting and welding activities related to your SAEP, refer to IMS #RB-221, Activities for
Agricultural Science 221. After completing an activity, be sure to record the entry in the journal page of your
Internet record book, and click on 221-E for the Course and Unit of Instruction.)
A SLEEPING GIANT
I am a compressed gas cylinder.
I weigh in at 175 pounds when filled.
I am pressurized at 2,200 pounds psi.
I have a wall thickness of about 0.25
I stand 57 inches off the deck.
I am 9 inches in diameter.
I wear a cap when not in use.
I wear valves, gauges, and hoses when at work.
I wear many colors and bands to tell what tasks I perform.
I transform miscellaneous stacks of materials into glistening
ships -- when properly used
I transform glistening ships into miscellaneous stacks of material
when allowed to unleash my fury unchecked.
I am ruthless and deadly in the hands of anyone careless or
uninformed.
I am too frequently left standing alone on my small base -- my
cap removed & lost by an unthinking workman.
I am ready to be toppled over -- where my unprotected valve can
be snapped off -- and all of my power unleashed through
an opening no larger than a #2 pencil.
I am proud of my capabilities - here are a few:
I have been known to jet away faster than any AA fuel
dragster on the NHRA circuit - over 800 mph;
I smash my way through brick walls with the greatest of
ease;
I fly through the air for distances of more than half a mile;
I spin, ricochet, crash, and slash through anything in my
path;
I scoff at the puny efforts of human flesh, bone, and muscle
to alter my erratic course;
I can penetrate a pickup truck from end to end;
I have been known to blast my way through four 14-inch
brick walls before running out of pressure.
My escaping oxygen exhaust burns everything in its path.
I can, under certain conditions, rupture or explode -- then,
you read about my exploits in the newspaper.
You can be my master ONLY under my terms:
Full or Empty, be sure my cap is on straight and snug;
Never, NEVER leave me standing alone;
Keep me in a secure rack or tied so that I cannot fall;
Treat Me With Respect, I am A SLEEPING GIANT
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small paintbrush
one-quart container
one pint liquid soap, or a soap and water solution
Procedure:
1.
Lay acetylene cylinder on its side and paint the soft plugs with the soap solution. A leak here will
cause bubbles to form.
2.
Stand the cylinder upright and paint the soft plugs on the shoulders of the bottle. DO NOT try to stop
leaks in or around soft plugs - call the dealer and have the cylinder replaced!!
3.
Paint the regulator receptacle or main opening before attaching the regulator. If the bottle shows a
leak now, this means that the main valve seat is damaged and leaking, regardless of how tightly the
cylinder valve is closed.
4.
Paint the main valve stem around the ring nut at the top of the valve. If a leak is present here, stop the
leak by tightening the ring nut with an adjustable wrench.
5.
Attach the regulator to the cylinder and open the cylinder valve; paint the regulator ring nut and
repaint the cylinder valve stem. Sometimes a cylinder may not leak at the cylinder valve stem until
after the regulator is attached and the valve is opened.
6.
Ask the distributor that any leaking bottles be replaced at their cost.
- 20 -
F
F
F
T
T
T
T
T
T
T
F
F
F
F
F
F
F
T
T
T
T
T
T
F
F
F
F
F
F
DISCUSSION: Following demonstration by your instructor, briefly discuss and complete the following activities.
28. Assemble the oxyfuel rig.
29. Turn on and adjust the oxyfuel rig.
30. Complete the shutdown of the oxyfuel rig.
SKILL PERFORMANCE ACTIVITIES: Following completion of this topic, practice the following skills
as assigned by your instructor.
31. Cutting with Oxyfuel
1.
2.
3.
Materials: Mild steel plate (1/4, 3/8, 1/2, 3/4, and 1 inch thick) and 2-inch pipe.
Objective: Cut and Pierce Plate; Cut Pipe
Procedure:
a. Clean the metal and mark the line to be cut.
b. Properly position the metal so that molten metal and sparks will fall into a container.
c. Select the correct tip and properly align the orifices.
d. Set the pressure and adjust to a neutral flame.
e. The cut can be made free hand or with a guide.
f.
Tilt or angle the torch depending on the thickness of the metal.
g. Cut in a straight line.
h. Cut a semicircle.
i.
Cut a circle.
j.
Pierce a 1/2-inch hole.
k. Cut a 90-degree angle on 2-inch pipe.
l.
Cut a saddle on 2-inch pipe.
Part 3:
1. Materials: 1/4-inch mild steel plate and mild steel welding rods (copper coated to prevent rusting
while in storage)
2. Objective: Fusion Welding With Filler Rod
3. Procedure:
a. Position metal joint and adjust torch flame to neutral.
b. Produce a live puddle.
c. Insert end of rod into the center of the puddle directly under the blue inner cone and proceed to
build a bead by oscillating both the rod and the torch, which are held at 45-degree angles to the
surface, and move forward at an even speed.
d. Keep the tip of the blue inner-cone at least 1/8 inch above the surface of the live puddle.
e. Examine for uniformity.
Part 4:
1. Materials: 1/4-inch mild steel plate; brazing rods; and general-purpose flux
2. Objective: Braze Welding With Filler Rod
3. Procedure:
a. Clean and position the metal.
b. Set torch to a neutral flame.
c. Heat the end of the rod and dip it into the flux until it is well coated.
d. Bring surface of steel to a cherry red heat (no puddle when brazing).
e. Braze the joint with brass by laying a thin coat of brass along the entire joint.
f.
Cut the flame down to 1/2 the original temperature and proceed to build up the bead with no flux
on second and/or third pass.
g. Examine for uniformity.
NOTE: Brazing cast iron uses the same technique as mild steel except a special flux must be used.
NOTE: Welding cast iron differs from welding mild steel in that a cast iron rod must be used with a special
flux. Allow the weld to cool slowly.
Acknowledgements
Praxair Distribution, Inc., provided valuable technical assistance in the revision of this topic.
Kirk Edney, Curriculum Specialist, Instructional Materials Service,
Texas A&M University, revised and edited this topic.
Vickie Marriott, Office Software Associate, Instructional Materials Service,
Texas A&M University, prepared the layout and design for this topic.
Christine Stetter, Artist, Instructional Materials Service,
Texas A&M University, prepared the illustrations for this topic.
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REFERENCES
FG2 High Technology Fuel and Cutting Equipment (brochure). Norcross, GA: Praxair/Chemweld, Inc.
Griffin, Ivan H., and Edward M. Roden. Welding Processes. Albany, NY: Delmar Publishers, Inc.
Herren, Ray and Cooper Elmer L. Agricultural Mechanics: Fundamentals and Applications. 4th ed.
Albany, NY: Delmar Publishers, Inc.
Morford, V. J., et al. Metals and Welding in Agriculture. Hobar St. Paul, MN: Publications, Inc.
Oxyfuel Cutting, Module 29101: Instructors Guide for AWS Entry Level Welder. National Center for
Construction Education and Research. Upper Saddle River, NJ: Prentice Hall Publishers, 2000.
Oxy-Gas Cutting. Materials Engineering (UK) Ltd. Derby, England, UK [May 27, 2002.] [On-line].
Available: http://www.meg.co.uk/ 1997
Safety in Welding, Cutting, and Allied Processes, ANSI Z49.1: 1999. Miami, FL: American Welding Society.
The Oxy-Acetylene Handbook. New York City, NY: Union Carbide Corporation - Linde Division.
Welding, Cutting, and Heating Guide. Denton, TX: Victor Welding and Cutting Division.
GLOSSARY OF TERMS
Brazing The joining of metals by adding bronze filler.
Coupon The metal plate prepared by weldors in the performance section of the AWS certification test.
Flashback When the oxyfuel mixture burns inside the torch handle.
Hardsurfacing The application of an all alloy material to another metal for the purpose of reducing wear.
MSDS Material safety data sheets.
Oxyfuel process The combination of pure oxygen and a combustible fuel gas to produce a flame.
Soldering The joining of metals by using lead and silver alloys as filler materials.
ADVANCED ACTIVITIES
1.
2.
3.
4.
Go to the Materials Engineering Group Web site and take the Oxy-Gas cutting test several times over
the course of this unit. Report your score to your teacher. Make a chart that documents your score
improvement.
Obtain some reject horseshoes from a local farrier. Practice your hardsurfacing technique on the toes
of the horseshoes.
Research the topic Nondestructive Testing. Report your findings to your agricultural science class.
Research and develop a presentation focused on the molecules involved in oxyfuel processes. Include
chemical formulas and molecular representations of the elements and compounds involved.
ALL RIGHTS RESERVED
Reproduction prohibited without written permission.
Instructional Materials Service
Texas A&M University
2588 TAMUS
College Station, Texas 77843-2588
http://www-ims.tamu.edu
2002
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