5
Gas Welding
Chapter Objectives
After completing this chapter, you will be able to:
5-1 Describe the history of oxyacetylene welding (OAW).
5-2 List and describe the properties and distribution
systems for the gases used for OAW.
5-3 Explain the safety issues of OAW.
5-4 List the equipment used for the OAW process.
Oxyacetylene Welding
Oxyacetylene welding (OAW), Fig. 5-1, page 138, is a
way to join metal by heating the surfaces to be joined to
the melting point with a gas flame, fusing the molten metal
into a homogeneous mass, and then letting it solidify into
a single unit. The flame at the cone reaches temperatures
as high as 5,800 to 6,300F. It is produced by burning
acetylene in an oxygen-rich gas atmosphere mixed in the
proper proportions in a welding torch. A filler rod may or
may not be used to intermix with the molten pool of the
metal being welded.
During the first part of this century, oxyacetylene
welding became the major welding process both for
fabrication and construction and for maintenance and
repair. It had wide application because it can be used to
weld practically all of the major metals. Today, however,
we find that its use is limited for industrial production
purposes. It is slower than the other welding processes,
and many of the prime metals such as aluminum, tita-
nium, and stainless steel can be welded more easily with
other processes. The oxyacetylene process is still used
for performing such operations as brazing, soldering,
and metalizing; welding metals with low melting points;
and general maintenance and repair work. Welding on
pipe with small diameters is still being done with the
oxyacetylene process, Fig. 5-2, page 138.
137
 While the oxyacetylene process is not used as much as
it once was, it has a wide enough application to make it a
necessary skill. It is an excellent means through which the
student welder can observe the effect of heat and the flow
of molten metal. It also develops the coordination of both
hands that is the basis of good technique for all welding
processes. In industry some jobs may require the ability to
weld with both the oxyacetylene process and the electric
arc process.

The History of Oxyacetylene Welding

The oxyacetylene process had its beginning many centu-
ries ago. The early Egyptians, Greeks, and Romans used
an alcohol or oil flame to fuse metals.
In the nineteenth century various gases were tested
in experimental welding. They were used in the labora-
tory and in working with precious metals. In 1847 Robert
Hare of Philadelphia fused platinum with an oxyhydro-
gen flame. In 1880 the production of oxygen and hydro-
gen through the electrolysis of water made possible the
distribution of these gases in cylinders under pressure.
Experiments were also done with oxygen-coal gas and
air-hydrogen flames in the late 1800s.
A number of discoveries led to the development of the
oxyacetylene process:
In 1836 Edmund Davey discovered acetylene gas.
Fig. 5-1 Welds made with the oxyacetylene process on steel In 1862 acetylene gas was produced from calcium
plate. They were welded in the vertical-up position. Gas welding carbide.
produces sound welds of good appearance. Welds can be applied In 1895 Thomas L. Willson began to produce calcium
in all positions.
carbide commercially. It was first used for residential
lighting.
In 1895 LeChatelier, a French chemist, announced
his discovery that the combustion of acetylene with
oxygen produced a flame hotter than any other gas
flame.
In 1900, Edmond Fouche, a Frenchman, invented a
high pressure acetylene torch. He later designed a low
pressure torch that worked on the injector principle.

A B OU T WEL DIN G

Fig. 5-2 Oxyacetylene welding a small diameter pipe on a
construction site. This is a radiant heating installation in the floor.
Thomas Willson
Thomas Willson had the foresight to look
at other uses for acetylene gas, and in 1903, after mixing
it with oxygen, created the oxyacetylene torch. It could
reach temperatures of 6,000F. This was hot enough for
welding or to use as a metal-cutting device. The torch was
quickly adopted by the automotive and shipbuilding indus-
tries and revolutionized both.

138Chapter 5Gas Welding

 In 1906 Eugene Bourbonville brought the first weld-
ing torch to this country. The process was first used
for maintenance and repair.
During World War I oxyacetylene welding came into
its own as a production tool.
include propane, natural gas, and a gas called by the trade
name of Mapp gas. At one time hydrogen was also used
extensively. Study the relative gas temperatures given in
Table 5-1. Figure 5-3 shows the type of cylinders for the
different gases, their sizes, and capacities.

Gases
The oxyacetylene welding process makes use of two prin-
cipal gases: oxygen and acetylene. However, a number of
other fuel gases can be used for cutting and heating. These
Oxygen
Oxygen is the gaseous chemical element in the air that
is necessary for life. It is the most abundant chemical
element in the crust of the Earth. It has no color, odor,
or taste. It does not burn, but by combining with other

Table 5-1 Various Fuel Gas Efficiencies

Combined Intensity
(usable heat) Btu (s/ft2 Oxygen per Ft3 Approx. Normal
Fuel Gas Btus (ft3) of flame cone area) Flame Temp.1 of Fuel1 Velocity (ft/s)
Acetylene 1,433 12,700 5,420F 1.04 17.7
Mapp 2
2,381 5,540 5,301F 2.4 7.9
Propane 2,309 5,500 5,190F 4.00 11.9
Natural gas3 918 5,600 5,000F 1.50 15.2
(Mpls./St. Paul)
Hydrogen 275 7,500 4,600F 0.25 36
1
All the figures above are based on neutral flame conditions. Slightly higher flame temperatures can be attained for most of these gases by burning them in an oxidizing flame.
Oxidizing flames require higher oxygen consumption. If the often quoted 6,300F temperature for acetylene were used, then figures for the other four gases would be respectively
higher.
2
Mapp gas data supplied by Dow Chemical Co.
3
Natural gas data vary with exact composition in different geographic areas. City gas is as low as 4,400F.

Fig. 5-3 Gas cylinder sizes

and capacities. Thermadyne
Industries, Inc.

Gas Welding Chapter 5139

elements, it supports their combustion. Substances that
burn in air do so much more vigorously in pure oxygen.
Other substances, such as iron, that do not burn in air will
do so in oxygen. It is this property that makes it useful in
cutting iron and steel.

Oxygen Production and Distribution

There are two commercial processes used in the produc-
tion of oxygen. One of these is the separation of air into ox-
ygen and nitrogen by liquefying the air. The other method
is the separation of water into oxygen and hydrogen by
the electrolysis of water, or in other words, by passing an
electric current through it. By far the greatest part of the
oxygen used commercially today is manufactured by the
liquefaction process.
Oxygen is distributed in steel or aluminum cylinders,
Fig. 5-4. Steel cylinders are made from a single plate of
high grade steel that has been heat treated to develop
maximum strength and hardness. Internal construction is
shown in Fig. 5-5. Because of the high pressure involved,
these cylinders undergo rigid testing and inspection. Oxy-
gen is also distributed in bulk tanks that are made accord-
ing to the same specifications.
The aluminum cylinders are typically used for medi-
cal gases and are generally of the smaller size. Typically
they are made of the high strength 6061-T6 series alumi- Fig. 5-5 Sectional view of an oxygen cylinder. Oxygen cylin-
num alloy. ders are seamless, drawn-steel vessels having a malleable iron
neck ring shrunk on at the top and a cylinder valve screwed into
Valve Mechanisms Each cylinder has a valve that must the neck.
be opened to release the oxygen. Some manufacturers
use a double-seated valve
that is perfectly tight when
completely open or closed,
Outlet Valve
Fig. 5-6. Valves that are not
Cap Cap fully opened or closed cause
oxygen to leak through the
stem and result in a serious
waste of materials. Other
manufacturers use a type of
valve that requires only a turn
or two to open. The valve is
protected from damage by
Oxygen Acetylene an iron cap that screws on
Cylinder Cylinder
the neck ring of the cylinder.
This cap should always be in
place except when the cylin- Fig. 5-6 This type of oxy-
der is in use. gen cylinder valve is double
Cylinders are charged seated to prevent leakage
with oxygen at a pressure of when open. It should always
be opened all the way. The
about 2,200 p.s.i. at 70F. An valve is constructed to oper-
Fig. 5-4 Cylinders of oxygen and acetylene. Thermadyne increase in the temperature ate efficiently under high
Industries, Inc. of the gas causes it to expand pressure.

140Chapter 5Gas Welding

and increase the pressure within the tank. A decrease in
temperature causes the gas to contract and reduce the pres-
sure within the tank. To prevent excess pressure, every
cylinder valve has a safety device to blow off the oxygen
long before there is any danger of explosion. Nevertheless,
cylinders should not be stored where they might become
overheated. If this occurs, the safety device will burst, and
the oxygen will be lost.
Capacity of Cylinder There are three cylinder sizes
generally used for welding and cutting. Gas suppli-
ers fill their tanks with varying amounts of gas. The
large size contains 220 to 244 cubic feet of oxygen. It
weighs about 148 to 152 pounds when full and 130 to
133 pounds when empty. The middle size contains 110
to 122 cubic feet of oxygen. It weighs 89 to 101 pounds
when full and 79 to 93 pounds when empty. A small
size has 55 to 80 cubic feet of gas and weighs about
67 pounds when full and 60 pounds when empty. All of
the oxygen in the cylinder may be used.
Safety in Handling It is important to remember that pure
oxygen under pressure is an active substance. It will cause
oily and greasy materials to burst into flame with almost
explosive violence. The following safety precautions
should be strictly observed:
Take special care to keep oil and grease away from
oxygen. Never store oxygen cylinders near oil, grease,
or other combustibles.
When using the cylinders, do not place them where
oil might drop on them from overhead bearings or
machines.
Never use oxygen in pneumatic tools or to start
internal combustion engines.
Never use oxygen to blow out pipe or hose lines,
dust clothes, or to create head pressure in a tank of
any kind.
Do not store oxygen cylinders near an acetylene genera-
tor, carbide, acetylene, or other fuel-gas cylinders.
Do not use the cylinder as a roller or lift it by the cap.
Keep cylinders away from the welding operation and
close the cylinder valve when work is completed.
Keep cylinders away from any electrical contact.
Acetylene
Acetylene is the most widely used of all the fuel gases,
both for welding and for cutting. It is generated as the
result of the chemical reaction that takes place when cal-
cium carbide comes in contact with water. Laboratory
tests have shown oxyacetylene flame temperatures up to
approximately 6,300F. Thus it has a very rapid rate of
preheating. Acetylene has a peculiar odor. If lighted, it
J OB T IP
Listening
Listening is as easy as breathingright?
Actually, no; it takes an active mind to listen on the job.
You must stop thinking about what you are going to say
next. Focus solely on understanding. After the person
finishes, repeat back, in your own words, what you have
understood.
burns with a smoky flame and gives off a great deal of
carbon as soot.
An effective welding fuel gas must possess the follow-
ing characteristics:
High flame temperature
High rate of flame propagation
Adequate heat content
Minimum chemical reaction of the flame with base
and filler metal
Acetylene most closely matches all these requirements
and is used for welding purposes. For heating and c utting,
other fuel gases can be used.
Acetylene Production and Distribution
Commercial acetylene is made from calcium carbide,
which is commonly referred to as carbide. Carbide is a
gray, stonelike substance that is the product of smelting
coke and lime in an electric furnace. It is distributed in
standard steel drums containing 100 pounds of carbide
for use in acetylene generators. Several sizes are avail-
able: lump (3 2 inches); egg, nut, quarter, or pea
( inch); rice and 14 ND (0.055 0.0173 inch).
Carbide is also available in a special form known as
carbic-processed carbide, which is carbide compressed
into briquets. The cakes are used in acetylene generators.
They are 4 3 inches and weigh about 2 pounds. They
are packed in drums containing 40 cakes each.
Like oxygen, acetylene is distributed in cylinders. (See
Fig. 5-4.) These cylinders are constructed differently from
oxygen cylinders because of the fact that free acetylene
should not be stored at a pressure above 15 p.s.i. After
much study, the problem of combining safety with capac-
ity was solved by packing the cylinders with a porous ma-
terial saturated with acetone, a liquid chemical having the
property of dissolving or absorbing many times its own
volume of acetylene. The cylinder itself is a strong steel
container. It is packed completely full. In such cylinders,
the acetylene is perfectly safe, but it is still considered to
Gas Welding Chapter 5141

Fig. 5-7 Three basic types of acetylene cylinders and their
internal construction.
be unstable and must be handled with care. Figure 5-7
shows three basic types of acetylene cylinders and their
internal construction.
Valve MechanismsAcetylene is drawn off through a
valve that in some cylinders is located in a recessed top;
and in others, on a convex top. This valve does not have to
stand the high pressure that the oxygen valve is subjected
to and is, therefore, much simpler in construction. It needs
to be opened only about 1 turns. This is done so that the
cylinder can be turned off quickly if a fire starts in any
part of the welding apparatus. Safety fuse plugs are also
provided.
Capacity of Cylinder A full cylinder of acetylene has a
pressure of about 225 p.s.i. Two sizes are generally used
for welding and cutting. The large size contains about
300 cubic feet of acetylene and weighs about 232 pounds
when full and 214 pounds when empty. The small size
contains about 100 cubic feet of acetylene and weighs
about 91 pounds when full and 85 pounds when empty.
Two special sizes containing 10 cubic feet and 40 cubic
feet are also available.
Not all the acetylene in the cylinder can be used. The
maximum practical use of the gas is reached when the
oxyacetylene flame begins to lengthen and loses much of
its heat. The acetylene pressure regulator reading will be
about 35 p.s.i. This varies with temperature.
Safety in Handling Remember that acetylene will burn,
and like any other combustible gas, it will form an
142Chapter 5Gas Welding
explosive mixture with air. The following pre-
cautions should be observed:
D o not leave acetylene cylinders on their sides.
Store and use them with the valve end up.
Store the cylinders in a well-protected, ven-
tilated, dry location. They should not be near
highly combustible material such as oil or
excelsior, or stoves, radiators, furnaces, and
other sources of heat. Keep the valve cap on
when the cylinder is not in use.
If the outlet valve becomes clogged with ice,
thaw it with warm (not boiling) water applied
only to the valve. The fusible safety plugs
with which all cylinders are provided melt at
the boiling point of water. Never use a flame
for thawing the valve.
Handle acetylene cylinders carefully. Rough
handling, knocks, and falls may damage
the cylinder, valve, or fuse plugs and cause
leakage.
If acetylene leaks around the valve spindle when the
valve on the cylinder is opened, close the spindle,
move the cylinder to an outside area, and advise the
supplier immediately. Only trained personnel should
service and repair cylinder valves.
Never tamper with the fuse plugs.
Propane Gas
Propane is a hydrocarbon present in petroleum and
natural gas. It is used primarily for oxyfuel heating, cut-
ting, soldering, and brazing. It is sold and transported in
steel cylinders containing from 20 to 100 pounds of the
liquified gas. It can also be supplied by tank car and bulk
delivery. The oxypropane flame temperature is approxi-
mately 5,190F. Because this temperature is less than that
of oxyacetylene, it takes longer to bring the steel to the
melting point. Propane is used extensively for soldering
and alloy brazing.
Mapp Gas
Mapp gas is a liquified acetylene compound that is a fuel
gas for oxyfuel heating and cutting. It has a strong smell
that is an aid in discovering leaks. When mixed with oxy-
gen, the flame has a temperature of 5,301F. This tempera-
ture is higher than that of the oxypropane flame but not
as high as that for the oxyacetylene flame. Although the
heating and cutting may be somewhat slower due to the
lower temperature, users indicate that overall expenses
are lower due to reduced handling costs and lower gas
costs. The use of this gas as a fuel gas for heating and
cutting is growing.
Mapp Gas Distribution Mapp gas is distributed in bulk
or in steel cylinders similar in appearance to acetylene
cylinders. They have a shutoff valve similar to that on
acetylene cylinders.
Capacity of Cylinder Although Mapp gas is an acetylene
product, it is liquified and stabilized so that it can be used
at pressures as high as 375 p.s.i. at 170F as compared
with 15 p.s.i. for acetylene. The explosive limits of Mapp
gas are lower than those of acetylene. Since the gas can be
stored in its free state and at high pressures, a 120-pound
cylinder contains as much gas as five 240-pound cylin-
ders of acetylene. This reduces handling cost for the user.
Safety in Handling Mapp gas, like all other flammable
gases, forms an explosive mixture with the air. The same
general precautions that have been recommended in the
handling of acetylene cylinders should be observed in the
handling of these cylinders. It is the safest of industrial
fuels. The explosive limits of Mapp gas vapor in air and
oxygen are much narrower than acetylene and about the
same as propane and natural gas. You can smell it at con-
centrations as low as 0.01 percent and find leaks that can-
not be detected with other gases.
General Cylinder Handling, Storage,
and Operation Safety Concerns
Information on general cylinder safety concerns is avail-
able from many sources such as OSHA Regulations
(Standards29 1910 Subpart Q Welding, Cutting, and
Brazing CFR1910.253). All oxyacetylene welders should
understand and follow these regulations:
1. All portable cylinders used for the storage and ship-
ment of compressed gases shall be constructed and
maintained in accordance with the regulations of
the U.S. Department of Transportation, 49 CFR
Parts 171180.
2. Compressed gas cylinders shall be legibly marked,
for the purpose of identifying the gas content, with
either the chemical or the trade name of the gas. Such
marking shall be by means of stenciling, stamping, or
labeling and shall not be readily removable. When-
ever practical, the marking shall be located on the
shoulder of the cylinder. This method conforms to
the American National Standard Method for Marking
Portable Compressed Gas Containers to Identify the
Material Contained, ANSI Z48.1-1954.
3. Compressed gas cylinders shall be equipped with
connections complying with the American National
Standard Compressed Gas Cylinder Valve Outlet
and Inlet Connections, ANSI B57.1-1965.
4. All cylinders with a water weight capacity of over
30 pounds (13.6 kilograms) shall be equipped with
means of connecting a valve protection cap or with
a collar or recess to protect the valve.
5. Cylinders shall be kept away from radiators and
other sources of heat.
6. Inside of buildings, cylinders shall be stored in a
well-protected, well-ventilated, dry location, at least
20 feet from highly combustible materials such as
oil or excelsior. Cylinders should be stored in clearly
identified assigned places away from elevators,
stairs, or gangways. Assigned storage spaces shall
be located where cylinders will not be knocked over
or damaged by passing or falling objects, or subject
to tampering by unauthorized persons. Cylinders
shall not be kept in unventilated enclosures such as
lockers and cupboards.
7. The valves on empty cylinders shall be closed.
8. For cylinders designed to accept a valve protection
cap, the cap shall always be in place, hand-tight,
except when cylinders are in use or connected
for use.
9. For fuel-gas cylinder storage inside a building,
cylinders, except those in actual use or attached
ready for use, shall be limited to a total gas c apacity
of 2,000 cubic feet or 300 pounds of l iquefied
petroleum gas.
10. Oxygen cylinders shall not be stored near highly
combustible material, especially oil and grease,
or near acetylene or other fuel-gas cylinders,
or near any other substance likely to cause or
accelerate fire.
11. Oxygen cylinders in storage shall be separated
from fuel-gas cylinders or combustible materi-
als (especially oil or grease), a minimum distance
of 20 feet or by a noncombustible barrier at least
5 feet high having a fire-resistance rating of at least
one-half hour.
SH OP TA L K
Citigroup Center
After 20 years, it was revealed that a
skyscraper in New York, Citigroup Center, almost toppled
over due to a structural weakness. The building had
been designed to have welded joints, but bolted joints
were used instead. When the mistake was noticed,
welders were flown in to weld all the joints. During these
repairs, a hurricane headed toward them. Fortunately, the
hurricane altered course and the welders were able to
complete the task.
Gas Welding Chapter 5143