OXY-ACETYLENE WELDING

PRESENTED BY-
SANDEEP NAIR
CB.EN.P2MFG15018
M.TECH (MFG. ENGG.)
AMRITA SCHOOL OF
ENGINEERING,COIMBATORE
 OXY-ACETYLENE WELDING
 It is the common method of gas welding.
 The oxy-acetylene welding process combines oxygen and
acetylene gas to provide a high temperature flame for
welding.
 This temperature provides enough heat to melt most metal.
 The chemical reaction between acetylene and oxygen is
exothermic in nature.
 Oxy-acetylene flame may also be used for all types of
brazing.
 Oxy-acetylene welding is a manual process.
OXY-ACETYLENE WELDING
 WORKING PRINCIPLE

 Gas welding is a fusion welding process in which welding is

done by heating workpiece with flames obtained from oxy-
fuel gases.
 In these process, a mixture in proper proportion of such as
acetylene, liquefied petroleum, methyl acetylene propadene,
natural gas and hydrogen with oxygen are burnt to get
flame.
 This flame can be used to melt metal and flame is directed
by welding torch.
 A filler metal is sometimes added, which is available as rod
or wire with or without flux.
HEAT AND TEMPERATURE OF FUEL GASES:

FUEL TEMPERATURE HEAT OF COMBUSTION

°F °C Btu/ft³ MJ/M³
ACETYLENE (C2H2) 5589 3087 1470 54.8

MAPP1 (C3H4) 5301 2927 5460 91.7

HYDROGEN (H2) 4820 2660 325 12.1

PROPYLENE (C3H6) 5250 2900 2400 89.4

PROPANE (C3H8) 4579 2526 2498 93.1

NATURAL GAS 4600 2538 1000 37.3

REQUIREMENT FOR OXY-ACETYLENE FLAME

OXYGEN SOURCE FUEL SOURCE

FIRE

IGNITION TEMPERATURE

FIG – COMBUSTION TRIANGLE

MATERIALS SUITABLE FOR OXY-ACETYLENE
WELDING

 Plain carbon steel and low –alloy steel.

 Cast iron (best results)
 Stainless steel
 Aluminum and magnesium
 Copper and copper alloys
 Mild steel
 lead
OXY-ACETYLENE WELDING(OAW)STATION
OXY-ACETYLENE WELDING EQUIPMENT

1. Oxygen gas cylinder

2. Acetylene gas cylinder
3. Oxygen pressure regulator
4. Acetylene pressure regulator
5. Oxygen gas hose (blue)
6. Acetylene gas hose (red)
7. Welding torch
8. Filler rods
9. Protective clothing for welders (apron, gloves,goggles)
10. Trolleys for cylinder transportation
 OXYGEN CYLINDERS

Oxygen cylinder incorporate

a thin metal “ pressure safety
disk” made of stainless steel
and are designed to rupture
prior to the cylinder to
becoming damaged by
pressure.
The cylinder valves should
always be handled carefully.
 OXYGEN CYLINDERS

Cylinders are regularly

re-tested using hydrostatic
(NDE) while in test.
Cylinders are regularly
chemically cleaned and
annealed to relieve
“jobsite” stresses created
by handling.
PRESSURE REGULATORS FOR CYLINDERS

Reduced high storage

cylinder pressure to lower
working pressure.
Most regulators have a
gauges for cylinder
working and working
pressure.
Regulator diaphragms
are made of stainless
steel.
 ACETYLENE CYLINDERS

Cylinders are filled with a very

porous substance “monolithic filler” to
help prevent large pockets of pure
acetylene form forming.
Cylinders have safety plugs in the
top and bottom designed to melt at
100°c.
Acetylene id extremely unstable in
its pure form at pressure above 15psi.
Acetone is also present within
cylinder to stabilize the acetylene.
 ACETYLENE VALVE
Acetylene cylinder shut off
valves should be only opened
¼ to ½ turn.
This will allow the cylinder
to be closed quickly in case of
fire.
Cylinder valve wrenches
should be left in place on
cylinder that do not have a
hand wheel.
OXYGEN AND ACETYLENE REGULATOR
PRESSURE SETTING

 Regulator pressure may vary with different torch style and

tip sizes.
 Common gauge setting for cutting
-1/4” material Oxy 30-35psi Acet 3-9 psi
- ½” material Oxy 55-85psi Acet 6-12 psi
- 1” material Oxy 110-160 psi Acet 7-15 psi
 The maximum safe working pressure for acetylene is
15psi.
 Oxygen regulators usually painted green and acetylene are
red.
 CYLINDER TRANSPORTATION

Never Transport cylinders without the safety cap in place.

Never Transport with the regulator in place.
Never allow bottle to stand freely. Always chain them to
a secure cart or some other object that cannot be toppled
easily.
 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 metal to be
welded.
 METHODS OF WELDING

Forehand technique is relatively used in thin metal. The torch point

in the same direction that weld is being done so that the heat is not
flowing into the metal as much as it could. The tip of torch is held 45°
angle, which direct some of the heat away form metal.
Backhand technique is used on heavier or thicker base metal. Torch
point in the direction opposite to that in which the weld is being done.
TYPES OF FLAMES USED IN OAW

1).CARBURIZING FLAME:
 These flame contain excess of acetylene.

 It is suitable for application of requiring low heat.

 Carburizing flame is used in welding of monel metal,

nickel, high-carbon steel and many of non-ferrous.

 Steel is not welded by using this flame.
TYPES OF FLAMES USED IN OAW

2).NEUTRAL FLAME:
 If acetylene and oxygen are present in equal

proportions(1:1),then neutral flame is produced.

 For most welding operations, neutral flame is used,

since it has least chemical effect on heated metal.

TYPES OF FLAMES USED IN OAW

3).OXIDIZING FLAME:
 If flame has high oxygen content (ratio of oxygen &

acetylene is 1.5:1), then oxidizing flame is produced.

 Such flame are used in welding of copper and copper

alloys(brass and bronze).

 This flame is harmful for steel because it oxidizes the

steel.
FLAMES ADJUSTMENT FOR OAW

METAL FLAME

MILD STEEL NEUTRAL

LEAD NEUTRAL

GREY CAST IRON SLIGHTLY OXIDISING

ALLOY STEEL NEUTRAL

ALUMINIUM SLGHTLY CARBURIZING

NICKEL ALLOY SLIGHTLY CARBURIZING

COPPER NEUTRAL
WELDING PARAMETER FOR WELDING
CARBON STEEL
Metal Welding tip Welding rod Oxygen Acetylene Welding
thickness orifice (mm) diameter Consumptio Consumptio Speed
(mm) (mm) n n (m/hr)
(m3/hr) (m3/hr)
0.8 0.57 1.6 0.031 0.0283

1.6 0.75 1.6 0.062 0.0566

2.4 0.92 1.6/2.4 0.156 0.1420 6.10

3.2 1.09 2.4/3.2 0.280 0.2550 4.88

4.8 1.32 3.2 0.498 0.4530 4.27

6.4 1.61 3.2/4.8 0.778 0.7080 3.66

8 1.85 3.2/4.8 0.935 0.8500 3.05

9.6 2.08 4.8 1.246 1.1330 2.74

12.7 2.37 4.8 1.869 1.6990 2.44

 MAIN HAZARDS
 Fire caused by heat, sparks, molten metal or direct contact
with the flame.
 Explosion when cutting up or repairing tanks or drums
which contain or may have contained flammable materials.
 Fire/explosion caused by gas leaks, backfires and
flashbacks.
 Fire/burns resulting from misuse of oxygen.
 Crushing or impact injuries when handling and
transporting cylinders.
NEW DEVELOPMENT IN OAW

FIG-1- PREVIOUS DESIGN: FIG-2- MODIFIED DESIGN:

 ADVANTAGES
 The equipment cost is low and requires little
maintenance.
 It is portable and can be used anywhere.
 The gas flame is generally more easily controlled.
 The process can also be used for cutting.
 Filler metal can be properly controlled.
 Can be used in all weld positions.
 LIMITATIONS
 The process is very slow. Therefore, it has been
largely replaced by arc welding.
 Proper operator training and skill are also
essential.
 In some cases, there is loss of corrosion resistance.
 Less efficiency ,since the heat transfer rate is poor
when compared to arc welding.
 Heat source is not concentrated ,a large area of
the metal is heated an distortion is likely to occur.
 APPLICATIONS
 Cutting a rail just before renewing the rails
A cutting torch is used to cut a steel pipe
Bicycle repair and tune up
Cutting of metal piece with OAW