TECHNOLOGY

Copyright 2002 TWI Ltd

TECHNOLOGY

OXYGEN SUPPLY - BLACK CYLINDER

ACETYLENE SUPPLY - MAROON CYLINDER.
REGULATORS TO REDUCE PRESSURES.
FLASHBACK ARRESTORS.
HOSES (COLOUR CODED)
NON RETURN VALVES
BLOWPIPE
NOZZLES (TO SUIT APPLICATION).

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TECHNOLOGY

MODE OF OPERATION:A fuel gas and oxidant gas are mixed together then fed
through a nozzle and burnt.
The nozzle is attached to a blowpipe which the welder
manipulates to melt the edges of the workpiece and so
form a weld pool.
Filler metal (in the form of rods) is added as required by
the welder
The weld pool is protected from atmospheric contamination
by the burnt gas products and can be made mildly oxidising
or reducing.
Copyright 2002 TWI Ltd

TECHNOLOGY

There are 3 main flame types

NEUTRAL :- Equal combination of each gas
Applications:- Fusion welding of most materials and brazing
OXIDISING:- An excess of oxygen
Applications:- Welding bronze, and zinc containing alloys (brasses)
CARBURISING:- An excess of fuel gas
Applications:- Hard facing, especially with Cr or tungsten
carbide rods. Slightly reducing for aluminium and High C steels
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TECHNOLOGY

NEUTRAL

Colourless flame
White cone

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TECHNOLOGY

OXIDISING

Blueish flame
Short pointed
white cone
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TECHNOLOGY

CARBURISING(REDUCING)

Ragged orange flame

Long pointed white cone
with feathery edge
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TECHNOLOGY

NOZZLE SIZE
GAS PRESSURES
GAS VELOCITY
TIP TO WORK DISTANCE
TRAVEL SPEED
TECHNIQUE:- LEFTWARD OR RIGHTWARD.

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TECHNOLOGY

MAINLY STEELS, SOME STAINLESS (WITH A FLUX),

ALUMINIUM (WITH A FLUX)
BRAZING AND BRONZE WELDING, COPPER, BRASS,
ALUMINIUM, CAST IRON.
IN THICKNESSES TYPICALLY UP TO 6 mm.
THE FLAME ACTS AS A GOOD CLEANING MEDIUM,
SO SOME SURFACE CONTAMINATION IS OFTEN
ACCEPTABLE.

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TECHNOLOGY

RODS:-

GASES:-

SIZE:1.6mm/2.4mm/3.2mm
TYPICALLY

SIZE:- CYLINDERS (SIZES VARY) OR

BULK SUPPLY

TYPE:TO SUIT PARENT

MATERIAL
CONDITION:SHOULD BE CLEAN

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TYPE:- FOR FUSION WELDING,

ACETYLENE IS REQD. FOR
BRAZING/BRONZE WELDING, OTHER
GASES CAN BE USED SUCH AS
BUTANE, PROPANE, NATURAL GAS
AND PROPRIETRY GASES (APACHI).
CONDITION:- SAFETY IS PARAMOUNT. CONSIDER RISK OF FIRE AND
EXPLOSION

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TECHNOLOGY

LACK OF FUSION AND PENETRATION

OVERHEATED WELD - CRACKING
SHAPE DEFECTS:- UNDERCUT, OVERLAP, POOR
WELD PROFILE ETC.
OXIDATION
UNEQUAL LEG LENGTHS (FILLET WELDS).
????

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TECHNOLOGY

BLOW BACKS
FLASHBACKS
COPPER ACETYLIDE
OXYGEN AND OIL
LEAKAGE
FIRE AND EXPLOSION
FUME
CYLINDER SECURITY (CHAINS AND STORAGE).
SUFFOCATION
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