Gas Welding Notes

I. Define Gas Welding: The joining of two metals together by melting them.
Melting is done by directing a gas flame over the base metal. A molten
puddle is formed which when added to with a filler rod a bead weld is
formed.

II. Gases used

1. Oxygen: O2 O-O
H H
2. Acetylene: CH2CH2 C-C
H H

III. Advantages of Gas Welding

1. Slower and easier to control.
2. Popular for general maintenance work.
3. Better for metals with lower melting points.
4. Higher flame temperature reached with acetylene.

IV. Stages of combustion

A. Primary combustion
1:1 ratio of oxygen to acetylene
O2 + CH2CH2 2 CO + 2H2
Flame is used for welding

B. Secondary combustion
2CO + 2H2 + O2 (Air) 2 H20 + 2C
Protective shield and preheating flame

2000 F
4000 F
6000 F
V. Equipment Used for Gas Welding
A. Cylinders
Based on cubic feet of capacity:

1. Oxygen: 244 ft3, 122 ft3, 80 ft3

2. Acetylene: 300 ft3, 100 ft3, 60 ft3

Packed in porous material saturated with acetone. Material holds
the acetylene.
B. Regulators
Reduce cylinder pressure to a suitable working pressure. Shows two
pressures.
1. Cylinder- shows how much gas is available
2. Working- shows how much gas is going through welding tip.

C. Cutting Torch
Mixing chamber: O2 and CH2CH2 are mixed to a 1:1 ratio
Needle control valves control the flow of gases.

D. Hose Connections
Brass fittings- DO NOT over tighten
CH2CH2- left handed threads

E. Hoses
Oxygen- green or black
Acetylene- red
Sometimes lined with powder
Keeps hoses dry
Purge hoses before first use

VI. Welders Clothing

1. Protective goggles- #5 shade lens
2. Fire-resistant gloves
3. Shop coat/ long sleeved shirt
4. Leather boots

DO NOT WEAR
1. Tennis shoes
2. Cuffed pants
3. Loose fitting shirts
VII. Preparing to Weld
A. Cleaning metal
1. Remove dirt, dust, rust, paint, grease, oil, etc.
Foreign material weakens weld and could catch fire.

B. Beveling the joint

1. metal or smaller, 45 degrees
2. metal bigger than 60 degrees

C. Lighting and Shutting Down

Lighting:
1. Check regulators- should be backed out
2. Open cylinder valves- oxygen, acetylene
3. Adjust oxygen working pressure- 15 psi
4. Adjust acetylene working pressure- 5 psi
5. Adjust flowing psi of oxygen- 15
6. Adjust flowing psi of acetylene- 5
7. Open acetylene torch valve turn
8. Light torch
9. Adjust flame to stop smoking
10.Open oxygen torch valve
11.Adjust to neutral flame
Shutting Down:
1. Turn off acetylene torch valve
2. Turn off oxygen torch valve
3. Close cylinder valves: acetylene, oxygen
4. Drain acetylene hose
5. Drain oxygen hose
6. Regulators- back out acetylene, oxygen
7. Check valves to see they are closed
8. Hang up hoses.
D. Flames
1. Carburizing: excessive acetylene
3 flames

Correct by: increasing flow of oxygen and/ or decreasing

flow of acetylene
 2. Neutral: 1:1 ratio of oxygen to acetylene
Pointed inner flame
Leave it alone!

3. Oxidizing: excessive oxygen

Small pointed inner flame, lighter blue in color
Correct by: increase acetylene and/ or decreasing oxygen

VIII. Problems that Occur

1. Backfire- flame goes out with a loud pop
Causes: holding welding tip too close to base metal
Oxygen not sufficient to maintain flame

2. Flashback- flame burns back up through hoses

SHUT TORCH DOWN IMMEDIATELY- SOMETHING IS WRONG

3. Shirt catches fire- standing too close to base metal

4. Hoses catch on fire- molten metal lands on hoses.

Correct by keeping hoses behind you.

IX. How to Weld

A. Angles
1. Work = 90 degrees
2. Lead = 45 degrees
 B. Methods
1. Forehand tip pointed towards direction of travel.
Best for thin metal- 1/8 or smaller, better control of puddle

2. Backhand-tip pointed away from direction of travel

Best for thicker metal 1/8 or bigger, filler rod placed between
puddle and flame.
Sound weld at greater speed.

Move tip in a circular motion. Hold filler rod at 45-degree angle, keep tip in outer
flame.

X. How to Cut
1. Set torch to neutral flame with oxygen lever depressed.
2. Set work and lead angles
3. Heat metal until cherry red and molten puddle starts to form
4. Back up about
5. Depress oxygen lever
6. Move forward
a. too slow- edges melt back together
b. too fast- will not cut all the way through; not enough heat put into
the base metal.