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MP II Lab Manual Experiment 2

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Uttakantha Dixit
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32 views5 pages

MP II Lab Manual Experiment 2

Uploaded by

Uttakantha Dixit
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Experiment: 2 Date:

Aim: To study and demonstrate Gas cutting and Gas welding operation

Objective(s)
1. Become familiar with Gas welding, Gas cutting, soldering and brazing processes
Student will be introduced to:
2. The gas welding equipment, related tools and the essential process safety
considerations
3. Types of work materials, filler rods and fluxes.

1.1 Gas welding and cutting

Gas Welding:
Gas Welding or Oxy-fuel gas welding is a general term used to describe any welding process
that uses a fuel gas combined with oxygen to produce a flame. The most commonly used fuel
is acetylene (C2H2) gas. The heat source is the flame obtained by combustion of oxygen and
acetylene. When mixed together in correct proportions within a hand-held torch or blowpipe,
a relatively hot flame is produced with a temperature of about 3300ºC (6000ºF). The
chemical action of the oxyacetylene flame can be adjusted by changing the ratio of the
volume of oxygen to acetylene.
The combustion of oxygen and acetylene (C2 H2) is a two-stage reaction. Chemical reactions
are as follows: -
Stage 1: In the first stage, the supplied oxygen and acetylene react to produce Carbon
Monoxide and Hydrogen. Approximately one-third of the total welding heat is generated in
this stage.
C2H2 + O2 = 2CO + H2 + heat
Stage 2: The second stage of the reaction involves the combustion of the CO and H2. The
remaining two-third of the heat is generated in Stage 2. The specific reactions of the second
stage are:
2CO + O2 = 2CO2 + heat
H2 + ½ O2 = H2O + heat

Laboratory Manual: <Manufacturing Process – II (20ME303P)> 1


Fig.2. 1: Gas Welding (Oxygen–fuel gas) process
1.2 Types of Flame
Types of flames:
Three different types of flames can be obtained by varying the oxygen–acetylene (or oxygen
fuel gas) ratio.
Neutral Flame: When the ratio of oxygen- Carburizing flame: Excess fuel compared
acetylene (or oxygen–fuel gas) is between to oxygen produces a carburizing flame.
1:1 and 1.15:1, all reactions are carried to The excess fuel decomposes to carbon and
completion and a neutral flame is hydrogen, and the flame temperature is not
produced. As the supply of oxygen to the as great (about 3050°C or 5500°F). This
blowpipe is increased, the flame contracts type of flame is mainly used for hard
and the white cone become clearly surfacing and should not be employed for
defined, assuming a definite rounded welding steel as unconsumed carbon may
shape. This type of flame is the one most be introduced into the weld and produce a
extensively used by the welder, who hard, brittle, deposit.
should make himself thoroughly familiar Filler Metals & Flux
with its appearance and characteristics.
Filler metals are used to supply additional
Oxidizing flame: A higher ratio of material to the weld zone during welding.
oxygen-acetylene (or oxygen–fuel gas), These consumable filler metals maybe
such as 1.5:1, produces an oxidizing flame, bare or flux coated. The purpose of flux is
which is hotter than the neutral flame to retard oxidation of the surfaces of the
(about 3600°C or 6000°F). With the parts being welded, by generating a
increase in oxygen supply, the inner cone gaseous shield around the weld zone.
will become shorter and sharper, the flame
will turn a deeper purple color and emit a
characteristic slight "hiss". An oxidizing
flame is only used for special applications.

Laboratory Manual: <Manufacturing Process – II (20ME303P)> 2


Fig.2. 2 Gas welding Flames

1.3 Gas Cutting

Gas Cutting or Oxyfuel-gas cutting, commonly called flame cutting, is the most common
thermal cutting process. The oxyfuel flame is first used to raise the metal to the temperature
where burning can be initiated. Then a stream of pure oxygen is added to the torch (or the
oxygen content of the oxyfuel mixture is increased) to oxidize the metal. The liquid metal
oxide and any unoxidized molten metal are then expelled from the joint by the kinetic energy
of the oxygen-gas stream. By moving the flame and oxygen jet (torch tip) progressively
forward, fresh metal and oxygen are brought together forming oxide or slag in molten form
and expelling it to form a gap, or kerf, as illustrated in figure 3. A balance must be achieved
among speed of movement, oxygen jet size, and intensity of flame to achieve a continuous
operation

Fig.2. 3 Welding Torch Fig.2. 4 Gas cutting of a metal plate

1.4 Gas Cutting/Welding Equipment:

The apparatus used in gas welding consists basically of an oxygen source and a fuel gas
source, regulators, hoses, non-return valve, check valve and torches.

Regulator: The regulator is used to control pressure from the tanks by regulating pressure
and flow rate of gas. It releases the gas at a constant rate from the cylinder despite the
pressure in the cylinder becoming less as the gas in the cylinder is used.

Hoses: The hose is usually a double-hose design i.e. there are two hose joined together.
The oxygen hose is green and the fuel hose is red.

Non-return valve: Between the regulator and hose and ideally between hose and torch on
both oxygen and fuel lines, a non-return valve and/or flashback arrestor should be
installed to prevent flame/oxygen-fuel mixture being pushed back into either cylinder and
damaging the equipment.

Laboratory Manual: <Manufacturing Process – II (20ME303P)> 3


Check valve: A check valve lets gas flow in one direction only. Not to be confused with
flashback arrestor, a check valve is not designed to block a shockwave. A check valve is
usually a chamber containing ball that is pressed against on end by a spring. Gas flow in a
particular direction pushes the ball out of the way while no flow or flow on the other way
lets the spring push the ball into the inlet thus blocking it.

Torches: The torch is the part that the welder holds and manipulates to make the weld. It
has a connection and valve for Oxygen and also a connection and valve for Fuel, a handle
for grasp, a mixing chamber for mixing of the fuel and oxygen, a tip where the flame
forms. A welding torch head is used to weld metals and can be identified by having only
two pipes running to the nozzle and no oxygen blast trigger. A cutting torch head is used
to cut metals and can be identified by having three pipes that go to an around 900 nozzle
and also by oxygen-blast trigger that provides oxygen to blast away material while
cutting.

Fig.2. 5 An oxyacetylene welding outfit


1.5 Machine Specifications and observations:

Line Diagram:

Laboratory Manual: <Manufacturing Process – II (20ME303P)> 4


1.6 Answer the following questions:

1. Which flame, oxygen is of same proportion with acetylene?


2. Oxy acetylene gas welding is a type of reaction?
3. What is the chemical formula of acetylene?
4. In chemical cleaning which solvent is used to wash the trimming surface?

Laboratory Manual: <Manufacturing Process – II (20ME303P)> 5

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