Workshop Practice Manual-1

Department of Mechanical Engineering

Galgotias University
Greater Noida, UP
 Contents
General description about welding process

Application of Welding

Safety precautions in welding shop

Oxy acetylene gas welding

Types of Flames
 Welding
The welding is a process of joining two similar or dissimilar metals by fusion,
with or without the application of pressure and with or without the use of
filler metal

The fusion of metal takes place by means of heat. The heat may be obtained
from blacksmiths fire, electric arc, electrical resistance or by chemical
reaction

The welding is extensively used in fabrication as an alternative method for

casting and forging and as a replacement for bolted and riveted joints

It is also used as a repair medium e.g., to reunite metal at a crank, to build up

a small part that has broken off such as gear tooth or to repair a worn surface
such as bearing surface
 Application of Welding

Automobile construction
Rail road equipment
Ships
Aircraft construction
Bridges construction
Storage tanks
Piping and pipe lines
Household furniture
Repair of broken and damaged parts
 Safety precautions in welding shop
Gas Welding
Always wear welding gloves while doing gas welding
Never play or get careless while using the gas welding equipment.
Combustible gas must be handled carefully.
Always use the spark lighter to light the torch
Strictly follow the procedure laid out in handling the cylinders, regulators and torches

Arc Welding
Never look at arc with naked eyes
Always use a shield while welding
Always wear the safety hand glove, apron and leather shoes
Ensure proper insulation and check before opening
Apply eye drop after welding is over to relieve the strain on eyes
 Oxy acetylene gas welding
Acetylene is a carbonaceous combustible gas. When it is burnt in presence of
oxygen gas in a controlled manner the combustion produces intense heat by
means of flame at the torch tip with a temperature of about 33000C which is
sufficient to melt a metal.
The flame is long, smoky and yellowish in color. However when oxygen is also
supplied in the mixing chamber and the mixture is ignited, the size of the
flame is reduces and it is not smoky.
The flame is bluish in color. The heat is produced due to following exothermic
chemical reaction that takes place when mixture of acetylene and oxygen is
burnt at the tip of the gas torch.
The heat so produced melts the metal
2C2H2 + 5O2 = 4CO2 +H2O + 624000 cal
Typical application of Oxy-acetylene welding includes welding of root run in
pipe and other multi-run welds, light fabrications like ventilation and air-
conditioning ducts, and motor vehicle repairs.
 Oxy acetylene gas welding
There are two ways for the Oxy-acetylene welding
High pressure system: In this method both oxygen and acetylene are derived for
use from high pressure cylinder
Low pressure system: In this system, oxygen is taken out as usual from high
pressure cylinder but acetylene is generated by the action of water on
carbide in a low pressure acetylene generator.

Figure: Oxy-acetylene welding outfits

 Types of Flames
Neutral flame
The neutral flame is most often used for the welding of most of the materials like low
carbon steels, cast steels, cast iron etc
The flame is produced when the gas mixture has equal volumes of acetylene and
oxygen. This flame has two distinct zones, a sharply outlined luminous cone and an
outer flame surrounding the cone

Oxidizing flame
The flame is produced when the amount of oxygen is slightly more than the
acetylene. In other words the oxidizing flame has higher proportion of oxygen than
acetylene. This flame is very short in length and sharper in shape. During the
combustion a hissing sound is produced at the tip of the torch. Again there are two
distinct zones; the inner flame is used for welding brasses, bronzes and cast iron.
The oxidizing flame is used for welding of Mn-steel, brass, bronze, alluminium, nickel
etc

Reducing or carburizing flame

This flame is produced when the oxygen is kept slightly less than acetylene. It has
three distinct zones. The inner cone is the brightest and is surrounded by a bluish
feathery flame. This flame is advantageous for non-ferrous metals, silver soldering
and hard facing. It is also used in creating surface fusion on steel.
Figure: The three types of oxy-acetylene flames
Thank You