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Gas Welding
1. Gas Welding 7
Although the oxy-acetylene process has been introduced long time ago it is still applied for its
flexibility and mobility. Equipment for oxyacetylene welding consists of just a few ele-
ments, the energy necessary for welding can be transported in cylinders, Figure 1.1.
3 2.5
2.0
2.0
1.43
propane
1.5 1.29 1.17
4
acetylene
0.9
oxygen
1.0
6
natural gas
air
5 0.5
8 0
7 ignition temperature [OC]
9 645 645
1 600 510
2
oxygen
490
natural gas
400
propane
air
335
300
acetylene
200
1 oxygen cylinder with pressure reducer
acetylene cylinder with pressure reducer 0
2
3 oxygen hose flame temperature with O2
flame efficiency with O2
4 acetylene hose flame velocity with O2
43 1350
5 welding torch 3200
acetylene
6 welding rod 2850
10.3 370
propane
8.5 330
7 workpiece 2770
natural gas
8 welding nozzle
0 k cm
9 welding flame C
KW
/cm2 /s
br-er1-01.cdr ISF 2002 br-er1-02.cdr ISF 2002
Process energy is obtained from the exothermal chemical reaction between oxygen and a
combustible gas, Figure 1.2. Suitable combustible gases are C2H2, lighting gas, H2, C3H8 and
natural gas; here C3H8 has the highest calorific value. The highest flame intensity from point
of view of calorific value and flame propagation speed is, however, obtained with C2H2.
2005
1. Gas Welding 8
gas exit
C2H2 tends to decompose already at a pres-
feed wheel
sure of 0.2 MPa. Nonetheless, commercial
quantities can be stored when C2H2 is dis-
grille
solved in acetone (1 l of acetone dissolves
sludge
approx. 24 l of C2H2 at 0.1 MPa), Figure 1.4.
to
sludge pit
br-er1-03.cdr ISF 2002
Acetylene Generator
Figure 1.3
Storage of Acetylene
Figure 1.4
2005
1. Gas Welding 9
Oxygen is produced by
gaseous fractional distillation of
cooling
nitrogen cylinder liquid air and stored in cyl-
air
inders with a filling pres-
bundle
sure of up to 20 MPa, Fig-
oxygen
ure 1.5. For higher oxygen
pipeline
liquid
oxygen liquid
air consumption, storage in a
tank car
liquid state and cold gasifi-
nitrogen
vaporized cation is more profitable.
Figure 1.5
filling
connection
still user
liquid gaseous
br-er1-06.cdr
Storage of Oxygen
Figure 1.6
2005
1. Gas Welding 10
In order to prevent mistakes, the gas cylinders are colour-coded. Figure 1.7 shows a survey
of the present colour code and the future colour code which is in accordance with DIN EN
1089.
The cylinder valves are
old condition DIN EN 1089 old condition DIN EN 1089
blue white grey brown also of different designs.
blue (grey) grey
Oxygen cylinder connec-
oxygen techn. helium
yellow brown red red tions show a right-hand
thread union nut. Acetylene
acetylene hydrogen
grey dark green grey vivid green
cylinder valves are
grey grey equipped with screw clamp
argon argon-carbon-dioxide mixture
retentions. Cylinder valves
darkgreen black grey grey
darkgreen for other combustible
nitrogen carbon-dioxide gases have a left-hand
br-er1-07.cdr ISF 2006
Figure 1.8
2005
1. Gas Welding 11
At a low cylinder pressure (e.g. acetylene cylinder) and low pressure fluctuations, single-
stage regulators
discharge pressure locking pressure
are applied; at higher cyl-
inder pressures normally
two-stage pressure regula-
tors are used.
The requested pressure is
set by the adjusting screw.
If the pressure increases
on the low pressure side,
the throttle valve closes the
br-er1-09.cdr ISF 2002
Figure 1.9
The injector-type torch consists of a body with valves and welding chamber with welding
nozzle, Figure 1.10. By the selection of suitable welding chambers, the flame intensity can be
adjusted for welding different plate thicknesses.
The special form of the mixing chamber guarantees highest possible safety against
flashback, Figure 1.11.
welding torch
The high outlet speed of injector or blowpipe
the escaping O2 gener- hose connection
coupling nut
for oxygen
ates a negative pressure mixer tube mixer nozzle oxygen valve A6x1/4" right
2005
1. Gas Welding 12
A neutral flame adjustment allows the differentiation of three zones of a chemical reaction,
Figure 1.12:
acetylene
oxygen
acetylene
Injector-Area of Torch
Figure 1.11
2005
1. Gas Welding 13
2-5
welding zone
3200C
2500C
1800C
1100C
effects in welding of steel
sparking foaming
400C spattering
consequences:
carburizing reducing oxidizing
hardening
br-er1-12.cdr ISF 2002 br-er1-13.cdr ISF 2002
hard flame
br-er1-14.cdr ISF 2002
2005
Figure 1.14
1. Gas Welding 14
By changing the gas mixture outlet speed the flame can be adjusted to the heat requirements
of the welding job, for example when welding plates (thickness: 2 to 4 mm) with the welding
chamber size 3: 2 to 4 mm, Figure 1.14. The gas mixture outlet speed is 100 to 130 m/s
when using a medium or normal flame, applied to at, for example, a 3 mm plate. Using a
soft flame, the gas outlet speed is lower (80 to 100 m/s) for the 2 mm plate, with a hard
flame it is higher (130 to 160 m/s) for the 4 mm plate.
Depending on the plate thickness are the working methods leftward welding and rightward
welding applied, Figure 1.15. A decisive factor for the designation of the working method is
the sequence of flame and welding rod as well as the manipulation of flame and welding rod.
The welding direction itself is of no importance. In leftward welding the flame is pointed at
the open gap and wets the molten pool; the heat input to the molten pool can be well con-
trolled by a slight movement of the torch (s 3 mm).
s
r=
1,5
~
flange weld
weld-rod flame
br-er1-15e.cdr ISF 2002 br-er1-16.cdr ISF 2002
2005
1. Gas Welding 15
ISF 2002
When working in tanks and confined
br-er1-17.cdr
Welding Positions I
spaces, the welder (and all other persons
present!) have to be protected against the
Figure 1.17
welding heat, the gases produced during
welding and lack of oxygen ((1.5 % (vol.) O2
per 2 % (vol.) C2H2 are taken out from the
ambient atmosphere)), Figure 1.19. The addi- PA
Figure 1.18
2005
1. Gas Welding 16
ess causes the appearance of a heated zone. During cooling, shrinking forces are generated
in the heated zone and lead to the desired shape correction.
welded parts
2005