JABATAN KEJURUTERAAN MEKANIKAL MECHANICAL WORKSYOP PRACTICE GAS WELDING NUR HALIZA BINTI AHMAD SUHAIMI 02DKM12F2011 DKM

1A ENCIK AZMIN BIN ABIT

INTRODUCTION Oxyfuel gas welding or commonly know as gas welding use flame as source of heat. The flame is produced from mixture of fuel gas and pour oxygen the flame meltsthe edges or surfaces of the joining metals. This allow the molten metal to flow together and form a solid continuous joint upon cooling Welding methods or processes which fall under oxyfuel gas welding group areoxyacetylene welding(OAW), oxyhydrogen welding(OHW),pressure gas welding(PGW)and air acetylene

LEARNING OUTCOMES At the end of this experiment, student should know: -How to using oxyacetylene gas. -Type of torch that are used -How to use filler rod with the valve

TOOLS AND EQUIPMENTS 1. Oxygen and acetylene gas cylinders for combustion. 2. Pressure regulator to adjust and stabilize the gas pressure. 3. Two-way valve to control the one way flow of oxygen and acetylene gas. 4. Gas hose to channel the gas from the cylinder to the torch. 5. Special key to lock or unlock the oxygen and acetylene gas cylinder valve. 6. Spark lighter to ignite the welding torch. 7. Some pieces of metal 8.Filler rod. 9.Fluxs. 10.Wire brush.

SAFETY PRECAUTIONS 1) Wear a face shield / safety glasses at all times. 2) Obtain permission before use. 3) Store separately -> Oxygen and Acetylene cylinders. 4) Chained Securely -> Equipment connected to compressed gas cylinders. 5) Store cylinders outdoors in a well ventilated area. 6) Keep caps on any cylinders not having regulators attached to them. 7) Follow specific procedures for turning systems on and off (ten steps listed above). 8) Never expose equipment to oil or grease -> Spontaneous fire possibility. 9) Always wear leather gloves and an apron

PROCEDURES PREPARING THE CYLINDERS FOR WELDING Slowly open the main valve of the acetylene tank and adjust the acetylene pressure regulator to 5PSI (pounds to square inch). Open the needle valve on the torch and adjust the pressure on the acetylene regulators to show 5PSI. Close the needle valve. Go through the same procedure for the oxygen cylinder but in 10PSI TURNING ON: 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 the end of the flame. Acetylene increased and oxygen turned on slowly. Acetylene increased slowly and oxygen more rapidly, to produce an intense, localized flame, capable of precise welding. Turn off the oxygen first, followed by the acetylene

PROCEDURES CARRYING A WELD POOL WITHOUT A FILLER METAL Obtain a piece of mild steel 1/16 to 1/18 thick. Be sure the surface is free of oil,dirt and scale Light the torch and adjust it for a neutral flame Hold the inner cone of the flame approximately 1/8 from the work and position the torch at a 45 angle to the workpiece.move the torch from the right side of the workpiece to the left side ,using a circular manipulation.left handed welders should reverse the direction of travel. 5) Maintain a consistent travel speed to prevent melt-through in the workpiece 6) Practice depositing beads without filler until properly beads are consistenly produced. 1) 2) 3) 4)

DEPOSITING BEADS WITH FILLER METAL Obtain a piece of mild steel 1/16 to 1/8 Be sure the surface is free of oil ,dirt and scale Light the torch and adjust it for a neutral flame Practice running consistent straight beads while manipulating the torch and the filler metal at the correct angles 5) As the torch is withdrawn at the end of the pass ,fill the crater by adding filler metal. 1) 2) 3) 4)

WELDING A BUTT JOINT IN FLAT POSITION 1) Obtain two pieces of metal 1/16 to 1/8 thick. 2) Place the workpiece on two firebricks.space for progressive spacing ortack weldthe workpieces together 3) Begin welding at the right end ,using the same torch and filler motion as when depositing beads with filler 4) Work the torch slowly to give the heat a chance to penetrate the joint.add sufficient filler metal to build up the weld about 1/16 above the surface.be sure the weld pool is large enough and the metal is flowing freely before dipping the filler metal 5) Maintain a molten weld pool 6) Advance the weld pool about1/16 with each complete motion of the torch while maintaining a uniform bead width 7) Uniform torch motion will produce smooth ,even ripples

WELDING A CORNER JOINT IN FLAT POSITION 1) Obtain two pieces of metal and tack weld to form a corner joint 2) Hold the torch on the end of the joint until a weld pool is formed 3) Manipulate the torch to maintain the weld pool along the entire joint using a technique similar to that used on the flange joint 4) Withraw the torch at the end of the joint to prevent burning a hole in the joint 5) If additional buildup is required ,filler metal may be added as the weld pool is carried along the joint

DISCUSSIONS 1) Slag Inclusion -Slag inclusions are compounds such as oxides, fluxes and electrode coating materials thatare trapped in the weld zone. -Welding conditions are important as well as with the control of welding process parameters, the molten slag will float to the surface of the molten weld metal and thuswill not become entrapped. Slag inclusions can be prevented by the following practices: -Cleaning the weld-bead surface by means of wire brush (hand or power) or a chipper before the next layer is deposited -Providing sufficient shielding gas. 2) Weld profile -Its effects on the strength and appearance of the weld, but also because it can indicate incomplete fusion or the presence of slag inclusions in multiple-layer welds. Underfilling -results when the joint is not filled with the proper amount of weldmetal. (Figure 30.20a). Undercutting -results from the melting away of the based metal and consequentgeneration of a groove in the shape recess or notch. Overlap -is a surface discontinuity (Figure b) usually caused by poor welding or by the selection of improper materials. A good weld is shown in figure c.11Figure 3: Examples of various defects in fusion welds

3) High amperage -The electrode will melt faster and molten puddle will be excessively large and irregular. -Excessive spatter will occur due to high amperage. Its a scattering of molten metal particles that cool to solid from near weld bead. Low amperage

-Not enough heat to melt the base metal and molten pool will be too small. -Lead to incomplete fusion -as both metals are not completely joined by the weld. -The correction for this problem would be to increase heat, slow travel speed and increase arc length

CONCLUSION As conclusion, the objective can achievable to do the practical welding. The student musthave skill to do the welding, used the knowledge and understanding of the theories, and also welding techniques are applied in the practical welding. The practical task have been completeand the report will accomplished to prove the student can be do the practical task of oxyacetylene welding.

REFERENCES Ivan H. Griffin, Edward M. Roden . Delmar Publishers, 1971 - Technology & Engineering http://en.wikipedia.org/wiki/Oxy-fuel_welding_and_cutting Buku teks kejuruteraan mekanikal tingkatan 4. Mohd. Nasir Bin Tamin, Nawawi Mohd Jan,Kaharrudin Bin Ismail. 2005 Dewan Bahasa dan Pustaka