Welding and Fabrication Notes Welding and Fabrication Notes

Welding and Fabrication notes Welding and Fabrication notes
UNIT 2 GAS AND ARC

WELDING PROCESSES
Fundamental principles of GAS Welding
Gas welding is the process in which a gas flame is used to raise the temperature of
the metals to be joined.
The metals are heated up to melting. The metal flows and on cooling it solidifies.
A filler metal may be added to the flowing molten metal to fill up cavity made during
the end preparation.

Many combinations of gases are used in gas welding. But the most common
of these is oxygen and acetylene.
Oxy-acetylene Welding
The process of oxy-acetylene welding can be used for almost all metals and
alloys for engineering purposes.
A high temperature flame (3200°C) can be produced by this method. There are
two systems of oxygen-acetylene welding.
High Pressure System: In this process the oxygen and acetylene are taken for
use from high pressure cylinders.
Low Pressure System: In this system oxygen is taken from high pressure
cylinder and the acetylene is produced by the action of Calcium carbide and
water.
CaC2 + 2H2O = Ca (OH)2 + C2H2
Introduction to Welding Technology Page 42 of 48 Instructor: Mr. Julius

(a) Principle of Oxy-acetylene Welding
A very hot flame is produced by burning of the gases coming through the torch tip.
The edges to be welded are heated up to melting.
A filler metal is also added to complete the welding. This molten metal
mixture when solidifies on cooling forms a welded joint.
Oxygen cylinder and acetylene cylinder are filled with gases.
Both the cylinders are attached with pressure gauges, regulators and cylinder
valves.
The cylinder containing oxygen is painted black whereas the acetylene
cylinder is painted maroon.
Hose pipes, are provided with eachcylinder.
These pipes are connected to welding torch
(b) Welding Process
To start welding, the acetylene control valve is turned first. When acetylene
comes out of the nozzle, it should be ignited with spark lighter.
It will give a yellow-colored smoke flame. After it, oxygen cylinder valve is
opened and supply is increased until a most suitable flame is obtained.
Then the flame is focused on the edges to be welded.
Flux and filler metal are also added with the heat of flame.
The edges and filler metal melt and a joint are formed after cooling of the
molten metal. The joint maybe formed with or without using filler metal.
(c) Applications
Oxy-acetylene welding is particularly used for sheet metal work.
All the metals can be welded with proper filler metals. Same equipment
may be used for cutting purposes.
(d) Advantages of Oxy-acetylene Welding
The main advantages of oxy-acetylene welding are given be low:
1. Equipment is cheap as compared to other welding process.
2. It can be used for welding of all types of metals.
3. Maintenance of equipment is very less.
4. It is a portable process.
5. It can be used for cutting of metals of small thickness.
6. It is specially used for sheet metal work.
(e) Disadvantages
1. It takes long time for heating the job as compared to the arc welding.
2. The heat affected area is more.
3. This is prone to corrosion and brittleness.
4. Gases are expensive and difficult to store.

TYPES OF GAS FLAMES
There are three types of gas flames:
Oxidizing Flame 2. Carburising Flame 3.Neutral Flame
a. Oxidizing Flame: When the volume of oxygen gas is more than the volume of
acetylene mixed into the torch. This flame is used for welding brass and is also
used for cutting the metals.
b. Carburising Flame: Whenthe volume of acetylene mixed is more than
oxygen, carburising flame is formed. This flame is used for welding nickel,
monel etc.
c. Neutral Flame: It is known as balanced flame. Oxygen and acetylene gases are
mixed in equal volumes. Neutral flame is used for normal welding of steel, cast
iron etc.
Fig. 3: Types of Flames
Gas Welding Techniques

There are two types of gas welding techniques:
1. Left ward welding
Left Ward Welding: In this welding the tip of the torch is held at 60 to 70°C to the plates.
And the filler rod is inclined at 30 to 40°C in opposite direction. In this method, the plate
edges are heated immediately after the molten metal. The torch tip and filler rod are
moved slowly in the direction towards left. The technique is illustrated in the Fig.4.
Fig. 4: Leftward Welding
2. Right ward welding
Right Ward Welding: In right ward welding the torch is kept at 40 to 50°C to the job to be
welded. Torch is moved towards right as shown in the Fig. 5. Right ward welding is done

for heavy sections only.
Fig. 5: Rightward Welding
Flux
The chemicals which deoxidize the metal surface and provide inert atmosphere around
the molten metal areknown as fluxes.
The main function of flux is given below:
To prevent oxides on the hot surfaces.
To reduce the viscosity of molten metal.
It maintains a steady arc in case of arc welding. Fluxes are available as liquid,
powder, paste and gas.
Powder flux is sprinkled on the surfaces to be welded or the filler rod is dipped
into the powder. Liquid & paste fluxes are sprayed on the surfaces to be welded.
Gas fluxes are used to form inert atmosphere around the joint to be welded
Filler
The rod which provides additional metal in completing the welding is known as filler.
The composition of filler metal should be the same as that of the metals to be welded.
Gas Welding Equipment
Details of Gas welding equipment are as under:
Oxygen Cylinder: As shown in Fig 6. Cylinder is made up of steel in capacity range
2.25 to 6.3 m3. The cylinders are filled with oxygen at about 150 kg/cm2 at 21°C. A
safety valve is also provided on it. The cylinder can be opened or closed by a wheel
which operates a valve. A protector cap is provided on the top of a cylinder to safeguard
the valve.
Fig. 6: Oxygen Cylinder
Acetylene Cylinder: As shown in Fig. 7. Acetylene cylinders are also made up of steel.
Gas is filled at a pressure of 18-20 kg/cm2. The capacity of the cylinder is about 10m3.
Regulator valve and safety valve are mounted on cylinder. Safety plugs are also

provided on the bottom of the cylinder. When filled into the cylinder, the acetylene is
dissolved in acetone.
Fig. 7: Acetylene Cylinder
Regulator: Regulator is used to control the flow of gases from high pressure
cylinder.A simple type of regulator is shown in the Fig. 8.
Fig 8: Regulator
Torch: Torch is a device used to mix acetylene and oxygen in the correct proportion and
the mixtureflows to the tip of the torch. Refer Fig. 9. There are two types of torches:
Low pressure or injector torches
Medium pressure or equal pressure torches
Fig.9: Welding Torch

Low Pressure or Injector Torch: These torches are designed to use acetylene at low
pressure. The pressure is kept very low up to 0.7 kg/cm2. But the oxygen pressure is
very high.
Medium Pressure or Equal Pressure Torch: In this type of torch the acetylene is taken
at a pressure equal to 1 kg/cm2, the oxygen is always supplied at high pressure. Both
types of torches are provided with two needle valves. One regulates the flow of oxygen
and the second valve controls the flow of acetylene. A mixing chamber is provided to
mix the gases.
Torch Tips : For different types of jobs, different tips are used. The size of the tip is
specified by the outlet hole diameter. More than one hole is also provided in tips. The tip
is screwed or fitted on the front end of the torch. Various types of tips are shown in the
Fig.10.
Fig. 10: Torch Tips
Goggles: Gas flames produce high intensity light & heat rays, which are harmful to
naked eye. To protect the eyes from these rays, goggles are used. Goggles also protect
the eyes from flying sparks.

Fig. 11: Goggles

Lighter: For starting the flame, the spark should be given by a lighter. Match sticks
should not beused, as there is risk of burning hand.
Fire Extinguishers : Fire extinguishers are used to prevent the fire that may break out
by chance. Sand filled buckets and closed cylinders are kept ready to meet such accidents.
Difference between High Pressure and Low Pressure Gas Welding

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Welding and Fabrication notes Welding and Fabrication notes

UNIT 2 GAS AND ARC

Fundamental principles of GAS Welding

the end preparation.

Introduction to Welding Technology Page 42 of 48 Instructor: Mr. Julius

Introduction to Welding Technology Page 43 of 48 Instructor: Mr. Julius

Fig. 3: Types of Flames

Gas Welding Techniques

Introduction to Welding Technology Page 44 of 48 Instructor: Mr. Julius

Introduction to Welding Technology Page 45 of 48 Instructor: Mr. Julius

Fig.9: Welding Torch

Introduction to Welding Technology Page 46 of 48 Instructor: Mr. Julius

Fig. 11: Goggles

Introduction to Welding Technology Page 47 of 48 Instructor: Mr. Julius

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