GAS W E L C O M E

AV.S Ram Prasad Fundamentals of Manufacturing Processes

 GAS WELDING

 It is a fusion welding process.

 Joins the metal by heat of combustion of air /

oxygen & fuel gases mixture.

 Intense heat (flame) thus produced melts & fuses

together edges of parts to be welded.
 OXY FUEL GAS WELDING
 It uses a fuel gas combined with oxygen to produce
flame.

 Flame is source of heat that is used to melt the

metals at the joint.
 OXY FUEL GAS WELDING

 In this kind of welding the heat required for welding

is obtained because of the flame that is obtained
due to the combustion of oxygen with fuel.

 Oxy fuel Gas welding is of two types:

1. Oxy acetylene welding

2. Oxy hydrogen welding

PRINCIPLE OF OPERATION
 PRINCIPLE OF OPERATION
 When acetylene is mixed with oxygen in correct
proportions in the welding torch & ignited, flame
resulting at the tip of torch is sufficiently hot to melt &
join the parent metal.

 Flames reaches to a temp. of 3200oC & can melt all

metals.

 Filler rod is added to molten metal pool to build up the

seam for greater strength.
 ADVANTAGES

 Portable & can be used for repair of fabrication

work.

 Oxy acetylene flame can be easily controlled.

 Cost & maintenance is low.

 Rate of heating & cooling is low.

 Good weld quality.

 DISADVANTAGES

 Heavy sections can’t be joined economically.

 Flame temp. is less than arc temp.

 Takes long time to heat up metal.

 Gases are expensive.

 Handling & storing of gas requires lot of safety

precautions.

 Skilled operator required.

 APPLICATIONS

 Ferrous & non ferrous metals.

 Thin materials can be joined.

 Automotive & aircraft industries.

 Sheet metal fabrication plants

 FUELS USED IN GAS WELDING

 Acetylene.

 Propylene.

 Liquefied petroleum gas (LPG),

 Propane.

 Natural gas.

 Hydrogen.

 MAPP (Methyl Acetylene Propadiene)

GAS WELDING EQUIPMENT
 APPARATUS
 Oxygen source

 fuel gas source

 Two pressure regulators.

 Two pressure gauges

 Two flexible hoses

 welding torch

 Safety devices (goggles, gloves)

GAS CYLINDERS

 Oxygen gas Cylinder is

long thin Black in Color.

 Fuel gas is Red color

short dia. short cylinder
of large dia.
TORCH AREA AND WELDING ZONE
TURNING ON: ( Friction Spark Lighter)
 Acetylene slowly turned on (quarter/half turn of
the needle valve) and ignited, producing a small
flame.

 At this stage, a small amount of soot/ smoke is

given off at the end of the flame.
 SECOND STAGE

 In this stage Acetylene is increased and oxygen

turned on slowly.
 THIRD STAGE

 Acetylene increased slowly and oxygen more

rapidly, to produce an intense, localized flame,
capable of precise welding.
TYPES OF FLAMES
 TYPES OF FLAMES

 Neutral

 Carburizing / reducing

 Oxidizing
 TYPES OF FLAMES: NEUTRAL

 Equal proportions of oxygen and acetylene

 Flame has temp. of 3260 ° c.

 It affects no chemical change on molten metal.

 NEUTRAL FLAME

It is recognized by the smooth and soft rounded inner cone. (light
blue colur)
 METALS THAT CAN BE JOINED

 Carbon steels

 mild steels

 C.I

 Copper

 Aluminum
 CARBONIZING/ REDUCING FLAME

• Ratio of oxygen to acetylene 0.9 to 1.

• Temp is of 3038 TO 3150 °c
 CARBONIZING/ REDUCING FLAME

 It can be recognized by acetylene feather which exists

between the inner cone & the outer envelope.
 CARBONIZING FLAME : ZONES

 hot inner cone (Luminous zone)

 White-hot acetylene feather (intermediate cone)

 outer envelope (blue colored)

 TYPES OF FLAMES: CARBURISING

 Outer flame envelope is loner than neutral flame & much

brighter in color.
 METALS THAT CAN BE JOINED

 Al alloys

 Monel metal

 High carbon steels

 TYPES OF FLAMES: OXIDIZING

 Ratio of oxygen to acetylene 1.2 to 1.5

 Light blue inner cone and the darker blue to colorless

outer cone
OXIDIZING FLAME
FLAME ADJUSTMENT FOR OXY ACETYLENE
WELDING
Metal Flame

Mild Steel Neutral

High Carbon Steel Reducing

Gray Cast Iron Neutral, Slightly oxidizing

Alloy Steel Neutral

Aluminium Slightly Carburizing

Brass Slightly oxidizing

Copper, Bronze Neutral, Slightly oxidizing

Nickel Alloys Slightly Carburizing

Lead Neutral
 FILLER MATERIALS

 It is necessary to use filler rod for a strong weld to

produce a strong joint in case of thicker sections.

 Used to supply additional material to the welding

zone.

 Rods and wires and will be compatible with the

metals to be welded.
 FILLER MATERIALS:
 These consumable filler rods may be bare or
coated with flux.
PRINCIPLE OF OXY ACETYLENE WELDING:

 Oxyacetylene welding is a gas welding process.

It is one of the oldest welding processes.

 A coalescence or bond is produced by heating

with a gas flame obtained from the combustion of
acetylene with oxygen with or without the
application of pressure and with or without the
use of filler metal.
PRINCIPLE OF OXY ACETYLENE WELDING:

 A welding torch is used to mix the gases in the

proper proportions and to direct the flame against
the parts to be welded.

 The molten edges of the parts then literally flow

together and, after cooling, form one solid piece.

 The molten pool is generally supplied with additional

metal called filler. Filler material depends upon
the metals to be welded.
 WELDING PROCEDURE:

 Prepare the edge to joined and maintain their

proper position using suitable clamps and fixtures.

 Open the acetylene valve and ignite the gas at

the tip of the torch.

 Open the oxygen valve and adjust the flame

according to the particular application.

 The torch should be placed such that the white

cone is at a distance of 1.5 to 3.0 mm gap from the
plate.
 WELDING PROCEDURE:
 The torch is held at an angle of 30 to 45 degrees from
the horizontal plate.

 The movement of torch should be at either oscillating

or circular.

 When filler rod is used it is necessary to hold it at a

distance of 10 mm from the flame and 1.5 to 3 mm
from the surface of the puddle.

 It gets preheated and it melts readily and has to

withdraw the rod after enough filler material has been
added.
 WELDING PROCEDURE:
 The preheating should be maintained by keeping
at proper distance which otherwise will cooling the
puddle or creating an uneven bead.

 For thicker plates require more than one pass of

the torch along the length to complete the joint.
This is called multi pass welding.

 In multi pass welding, the first pass (root pass) is

very critical in any welding operation.
 WELDING TECHNIQUES
 Depending upon the ways in which welding rod &
welding torch may be used, these are classified as:

1. Leftward technique or forehand welding method.

2. Rightward technique or backhand welding method.

 LEFTWARD WELDING

 After edge preparation of joint weld is commenced at right-hand

side of joint.

 Blow pipe is given steady forward movement along the left.

 LEFTWARD WELDING

 Welder holds torch in his right hand & filler rod in left.

 Weld is commenced on right-hand side of seam.

 LEFTWARD WELDING

 Usually used on thin metals. (< 5mm thick metals)

 Vertical joints are welded by this technique.

 C.Iron & non-ferrous metals

 RIGHT WARD WELDING

 Welding begins at left hand end of joint and proceeds

toward right.
 RIGHT WARD WELDING

 Torch flame is directed towards completed weld.

 Filler rod remains between flame & completed weld section.

 RIGHT WARD WELDING

 Used on heavier / thicker base metals.

 Better weld qualities can be obtained.