MEM05 Metal and Engineering

Training Package

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MEM05004C
Perform routine
oxyacetylene welding

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Learner guide
Version 1

Training and Education Support

Industry Skills Unit
Meadowbank

Product Code: 5539

MEM05004C Perform routine oxyacetylene welding

Acknowledgments
The TAFE NSW Training and Education Support, Industry Skills Unit Meadowbank
would like to acknowledge the support and assistance of the following people in
the production of this learner resource guide:
x
x

BOC Gases
CIGWELD

Writer
Ed Harkness (from existing TAFE material)

Reviewer

Vince Aranda (Illawarra Institute)

Stephen Davies
Educational Program Manager
TAFE NSW

Enquiries

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Project Manager

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Enquiries about this and other publications can be made to:

Training and Education Support Industry Skills Unit, Meadowbank
Meadowbank TAFE
Level 3, Building J
See Street
MEADOWBANK NSW 2114
Tel: 02-9942 3200

Fax: 02-9942 3257

TAFE NSW (Training and Education Support, Industry Skills Unit

Meadowbank) 2012
Copyright of this material is reserved to TAFE NSW Training and Education
Support, Industry Skills Unit Meadowbank. Reproduction or transmittal in
whole or in part, other than subject to the provisions of the Copyright Act, is
prohibited without the written authority of TAFE NSW Training and Education
Support, Industry Skills Unit Meadowbank.

ISBN 978-1-74236-275-5

TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2012

MEM05004C Perform routine oxyacetylene welding

Table of contents
Introduction .................................................................................. 5
1.

General introduction ........................................................................... 5

2.

Using this learner guide ...................................................................... 5

3.

Prior knowledge and experience ........................................................... 7

4.

Unit of competency overview ............................................................... 7

5.

Assessment ..................................................................................... 10

Topic 1: Oxyacetylene welding safety .......................................... 15

Weld fumes ........................................................................................... 15

Use protective clothing and equipment (PPE) ............................................. 16

Topic 2:

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Review questions.................................................................................... 20

The oxyacetylene welding process .............................. 23

Equipment ............................................................................................. 24

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Review questions.................................................................................... 31

Practical jobs ............................................................................... 35

Job 1: Lines of fusion and bead welds ....................................................... 36
Job 2: Pad weld - flat .............................................................................. 38
Job 3: Corner fillet weld - flat................................................................... 40
Job 4: Corner fillet weld - horizontal/vertical .............................................. 42
Job 5: Lap fillet weld - flat ....................................................................... 44
Job 6: T-fillet weld - horizontal/vertical ..................................................... 46
Job 7: Butt weld - flat ............................................................................. 48
Project: Composite welded structure ......................................................... 50

Resource Evaluation Form ........................................................... 53

TAFE NSW (Training & Education Support, Industry Skills Unit Meadowbank) 2012

MEM05004C Perform routine oxyacetylene welding

Topic 1: Oxyacetylene welding safety

Oxyacetylene welding is a safe welding process provided it is used in the correct
manner and strict welding safety guidelines are followed. As well as the welding
operator, oxyacetylene welding can injure others in the area where welding is taking
place.

Safety hazards
Typical safety hazards associated with this welding process include:
Burns
Burns caused by:
touching hot metal
hot torch parts, hot filler rods or sparks coming in contact with exposed skin
heat of the flame.

x
x
x

Weld fumes
Fumes are given off from:

metals being welded

oxides or surface coatings on metal parts being welded
cleaning solvents used on metal surfaces prior to welding.

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x
x
x

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Burns from welding can cause discomfort and will often require first aid attention.

Care should be taken when selecting surface cleaning agents. Manufacturers

information should stipulate that the cleaning agent is safe to use in the presence of
welding.
Weld fumes can cause discomfort after a short period of exposure. Some types of
weld fumes can cause serious respiratory problems over a longer period of time. In
general, weld fumes can cause respiratory problems for welding operators and others
nearby.
Infra-red rays
The bright light emitted from the welding flame emits infra-red rays. These rays are
dangerous and can cause permanent injury to eyes through long term unprotected
exposure. Excessive exposure to the heat from the oxyacetylene flame can also cause
fatigue to operators, especially when using large welding flames.
Compressed gases
Cylinders used for oxyacetylene welding contain gases stored at high pressures. It is
important that they are handled, used and stored carefully according to the suppliers
recommendations and instructions.
x

Never USE OIL on any oxygen cylinders or fittings

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MEM05004C Perform routine oxyacetylene welding

x
x
x

Cylinders should be used and stored in the upright position at all times, and
secured to avoid falling over
Gases should not be used for any other purposes than that of welding
(See Hazards of Industrial Gases for more details).

Safety precautions
To protect yourself and others from injury it is essential that the following safety
precautions are observed:

Use protective clothing and equipment (PPE)

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This includes:
x overalls or heavy drill cotton long trousers and long-sleeve shirt made from
non-flammable material
x safety footwear with leather uppers and rubber soles
x welders leather gloves/gauntlets
x Australian standards approved welding goggles with correct filter lens shade
(e.g. Shade 5-6; see table below)
x wearing standards approved safety glasses when working near welding
operators.

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Note: Clothing worn by the welding operator should be in good repair. Frayed
clothing is a fire hazard. Lightweight clothing is not suitable for the intense heat
emitted from fuel gas welding. New clothing should be washed to remove starching
agents which have been known to be flammable. Old, worn clothing should be
discarded as the garment may ignite due to general wear and tear and deterioration
of the fibres.
Never leave butane cigarette lighters in your pockets whilst welding as this
can result in an explosion causing serious injury or death.

Oxyacetylene welding
goggles

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MEM05004C Perform routine oxyacetylene welding

Selection of filter lens

Shade of filter lens

Applications

General oxyacetylene welding, brazing, braze

welding oxyacetylene welding cast iron and
hard facing.

For welding pre-heated cast iron and thicker

sections of material.

You should seek expert advice before selecting a filter lens shade lower than those
listed above.
Welding screens

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In an open workshop or construction site, erect a welding screen made from

non-reflective material. This will protect others nearby from the effects of
stray welding sparks
It is important to warn others working nearby that welding about to
commence
Safety glasses should be worn at all times by both the welding operator and
others working nearby.

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Portable screens make the workplace safer

for other workers

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MEM05004C Perform routine oxyacetylene welding

Hazards of industrial gases

Oxygen (O2)
Oxygen by itself is not flammable or explosive. However, it will support combustion
and cause material to burn freely. Be extremely careful as it will form highly
combustible and explosive mixtures. Oxygen must NEVER be used:
x
x
x
x
x
x

to operate pneumatic tools

for spray painting
as a substitute for compressed air
to blow out pipelines, vessels or containers
to freshen the air or clear fumes in a confined space
to cool yourself or blow dust from clothing.

Acetylene (C2H2)

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Acetylene is an industrial fuel gas. It produces a large amount of heat and in the
oxyacetylene flame attains the highest flame temperature of any known mixture of
combustible gases of about 3,100 C.
The gas is dissolved in liquid acetone in the cylinder and full cylinder pressures are
1550 kPa.
Safe use of acetylene gas includes;
keeping cylinders upright
dont transfer the gas from one cylinder to another
storing cylinders upright in a cool, well ventilated location.

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x
x
x

Sparks emitted from the flame

and weld pool

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MEM05004C Perform routine oxyacetylene welding

Adequate ventilation
Methods of ensuring that the air is safe to breathe are:
x

natural ventilation:
Occurs in a workshop that has large doors and windows, the natural
movement of air will help reduce the concentration weld fumes
x forced fume extraction:
Often required if welding in a confined space or where there is little air
movement a forced fume extraction system must be used
x respirators:
wear a standards-approved welding respirator when natural or forced
ventilation are not sufficient methods of reducing weld fume concentrations.
-

Other methods of limiting exposure to fumes include:

Keeping your head out of rising fumes from the weld area
Avoid breathing in fumes from metals such as stainless steel and nickel/nickel
alloys, and coated metal surfaces like galvanised steel
Using ventilation and respirators when welding these materials.

x
x

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Care should be taken when selecting surface cleaning agents. Manufacturers

information should stipulate that the cleaning agent is safe to use in the presence of
welding.

Fume extractor providing safer work environment

for welding operators

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MEM05004C Perform routine oxyacetylene welding

Review questions
The following questions have been included to help you revise what you have learnt
in Topic 1: Oxyacetylene welding safety.

1. List three (3) safety hazards associated with the oxyacetylene welding process.
x

___________________________________________________________

___________________________________________________________

___________________________________________________________

2. Name four (4) items of protective equipment/clothing a welding operator should

wear when oxyacetylene welding.
___________________________________________________________

___________________________________________________________

___________________________________________________________

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3. State the recommended shade of filter lens for oxyacetylene welding.

_____________________________________________________________

4. List three (3) safety precautions that must be observed when handing and
storing compressed gas cylinders.
x

___________________________________________________________

___________________________________________________________

___________________________________________________________

5. List two (2) methods common used to ensure adequate ventilation is present to
protect operators from welding fumes.
x

___________________________________________________________

___________________________________________________________

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MEM05004C Perform routine oxyacetylene welding

6. State the name of the bright light emitted from the welding flame.

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