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EQUIPMENT
Note:
The most common gases used as a fuel gas includes acetylone, hydrogen,
and methylacetylene.
To ensure correct connections, all screw threads on acetylene fittings are left-
handed, whereas those for oxygen are right-handed. Oxygen regulators are
usually painted green, and acetylene regulators red.
TYPES OF FLAMES IN OFW
The proportion of acetylene and oxygen in the gas mixture is an important
factor in oxyfuel gas welding.
Neutral flame: With a ratio of 1:1, when there is no excess oxygen, the flame
is considered to be neutral.
Oxidizing flame: With a greater oxygen supply, the flame can be harmful
because it oxidizes the metal , hence known as oxidizing flame.
Carburizing flame: If the oxygen is insufficient for full combustion, the flame
is known as carburizing flame.
FILLER METALS
Filler metals: Filler metals are used to supply additional
metal to the weld zone during welding, They are available
as filler wire or rods as shown in the figure. They are
usually coated with flux.
FLUX AND SHIELDING GAS
Flux: It is used to prevent oxidation and used to decompose surface
oxides. The purpose of the flux is to hold or slow down the oxidation
of the surfaces being welded by generating a gaseous shield around
the weld zone.
Oxidation: With a greater supply of oxygen (in oxidizing flame) an
oxide film is produced on the surface of the welding material which
can become hindrance between the filler and the welding material
and reduces the weld quality.
Shielding gas: Shielding gases are inert gases (argon, neon, helium
etc) that are commonly used in several welding processes. Their
purpose is to protect the weld area from water vapours, nitrogen,
carbon dioxide and excess of oxygen to avoid oxidation. Depending
on the materials being welded, these atmospheric gases can reduce
the quality of the weld or make the welding process more difficult to
use.
ARC WELDING PROCESSES
In arc welding, the heat required is obtained through
electrical energy. An arc is produced between the tip of
the electrode and the parts to be welded.
• Consumable electrodes
• Non-consumable electrodes
ARC WELDING PROCESSES:
CONSUMABLE ELECTRODE
Arc welding (consumable electrode) includes several
processes;
Submerged arc welding demonstration at the Essen Welding Fair in Germany, 2005. The welding head moves
from right to left. The flux (powder) is supplied on the left hand side, then follow three filler wire guns and finally a
vacuum cleaner.
GAS METAL ARC WELDING
Figure (a): gas metal-arc-welding process, formerly known as MIG (metal inert
gas) welding and (b): Basic equipment used in gas metal-arc-welding operations.
GAS METAL ARC WELDING (GMAW)
In gas metal arc welding
(GMAW) the weld area is shielded
by inert gases (argon, helium or
other gas mixture).
Figure (a): Gas tungsten-arc-welding process, formerly known as tungsten inert gas (TIG)
welding and Figure (b): Equipment for gas tungsten-arc-welding operations.
GAS TUNGSTEN ARC WELDING (GTAW)
In gas tungsten arc welding (GTAW)
a filler metal is typically supplied from
a filler wire (rod) as shown in the
figure. Tungsten
electrode