Oxygen-Acetylene Welding

Oxygen tank (green) Acetylene tank (red, or black with a red top) Oxygen pressure valves have a right-hand internal thread Acetylene pressure valve has an external lefthand thread. An oxygen-acetylene flame is very hot, approaching 3300C Filler rod is used when an additional supply of metal to weld is required. Shielding flux may be used if protection of weld pool is necessary.

Oxyacetylene Welding (OAW)

Oxyacetylene Welding is a Gas Welding process using a combustion

mixture of acetylene (C2H2) and oxygen (O2) for producing gas welding flame. Oxyacetylene flame has a temperature of about 6000F (3300C). Combustion of acetylene proceeds in two stages:

1. Inner core of the flame. C2H2 + O2 = 2CO + H2

2. Outer envelope of the flame: CO + H2 + O2 = CO2 + H2O Acetylene is safely stored at a pressure not exceeding 300 psi (2000 kPa) in special steel cylinders containing acetone. Outside of cylinder acetylene is used at a absolute pressure not exceeding 30 psi (206 kPa). Higher pressure may cause explosion.

Oxyhydrogen Welding (OHW)

Oxyhydrogen Welding is a Gas Welding process using a

combustion mixture of Hydrogen (H2) and oxygen (O2) for producing gas welding flame.

Oxyacetylene flame has a temperature of about 4500F (2500C). Combustion reaction is as follows: 2H2 + O2 = 2H2O
Oxyhydrogen Welding is used for joining metals with low melting points, like aluminum, magnesium, etc.

1. Gas Cylinders Pressure Oxygen 125 kg/cm2 Acetylene 16 kg/cm2 2. Regulators Working pressure of oxygen 1 kg/cm2 Working pressure of acetylene 0.15 kg/cm2 Working pressure varies depends upon the thickness of the work pieces welded. 3. Pressure Gauges 4. Hoses 5. Welding torch 6. Check valve 7. Non return valve

 Oxygen is turned on, flame immediately changes into a long white

inner area (Feather) surrounded by a transparent blue envelope is called Carburizing flame (30000c)
Addition of little more oxygen give a bright whitish cone surrounded by

the transparent blue envelope is called Neutral flame (It has a balance of fuel gas and oxygen) (32000c) Used for welding steels, aluminum, copper and cast iron
If more oxygen is added, the cone becomes darker and more pointed,

while the envelope becomes shorter and more fierce is called Oxidizing flame Has the highest temperature about 34000c Used for welding brass and brazing operation

Three basic types of oxyacetylene flames used in oxyfuel-gas welding and cutting operations: (a) neutral flame; (b) oxidizing flame; (c) carburizing, or reducing flame.

(c) carburizing, or reducing flame.

Oxy Fuel Gas Flame Cutting

It is an oxygen cutting process wherein the severing of

metals is effected by means of the chemical reaction of oxygen with the base metal at elevated temperatures. The necessary temperature being maintained by means of a gas flame obtained from the combustion of a fuel gas (such as acetylene, hydrogen, propane, etc.) and oxygen.

Schematic layout of oxy-flame gas cutting process

Components involved:
Gas cutter
O2 cylinder and fuel cylinder

Hose pipes

Pressure gauges

Gas cutter

Principle of operation:
The oxy hydrogen flame cutting process makes use of a

cutting torch. It mixes the hydrogen and the oxygen in correct proportions to produce a preheating flame and also the torch supplies a uniformly concentrated stream of high purity oxygen (known as cutting oxygen) to the reaction zone.

 A spot area along the line of cut is heated to ignition

temperature (900C), i.e., upto reddish yellow colour by the preheat flames.
By keeping the flame cones 1.5 to 3 mm above the

surface of material, to be cut, a thin jet of high purity oxygen is then directed or shot at this heated spot.

 The jet quickly penetrates through the steel.

The iron and oxygen combine to form iron oxide.

The oxygen jet blows the reaction products from the

joint and thus the torch moves progressively forward over the metal surface, cutting a narrow slot or kerf along the desired line of severance.

Fig showing Preheat and cutting streams

Welding Power Sources

Two classifications Output slope

Whether constant current or constant voltage

Power source type Transformer Transformer-rectifier Inverter Generator

Typical Output Slopes

Type oftypes Output Slope Two basic

Constant current

Referred to as variable voltage

Constant voltage

Referred to as constant potential

Each arc welding process has characteristic output

slope
SMAW and GTAW require steep output slope from

constant current welding machine GMAW and FCAW require relatively flat output slope from constant voltage power source

Open Circuit Voltage

Voltage generated by welding machine when no

welding being done

Machine running idle

Arc voltage Voltage generated between electrode and work during welding Load voltage Voltage at output terminals of welding machine when arc is going Combination of arc voltage plus voltage drop in welding circuit

Open Circuit and Arc Voltage

Open circuit voltage runs between 50-100 volts Drops to arc voltage when arc struck Arc voltages Range: 36 volts (long arc) to 18 volts (short arc) Determined by arc length held by welder and type of electrode used Arc lengthened, arc voltage increases and current

decreases

 Open circuit voltage on constant current machines

higher than on most constant voltage machines Arc voltage depends on physical arc length at point of welding and controlled by welder
Shielded metal arc welding
Gas Tungsten arc welding

Arc voltage much lower than open circuit voltage

 Maximum allowable used for manual welding 80 volts for a.c. or a.c.-d.c. machines 100 volts for d.c. machines

Very smooth output (less than 2% ripple)

Automatic machine welding Some constant current machines rated up to 125 Constant voltage types normally rated from 15 to 50

Four Types of Power Source

Engine-driven generators Powered by gas or diesel combustion engine Can be found with a.c. or d.c. electric motor

No longer being manufactured and rarely found

Transformer-rectifiers Use basic electrical transformer to step down a.c. line power voltage to a.c. welding voltage Welding voltage then passed through rectifier to convert a.c. output to d.c. welding current May be either d.c. or a.c.-d.c. machines

 A.C. transformers
Used to step down a.c. line power voltage to a.c. welding

voltage

Inverters
Increases frequency of incoming primary power Constant current, constant voltage, or both Produce a.c. or d.c. welding current

Polarity Switch
Electrode negative and electrode positive used in d.c.

welding DCEN (d.c. electrode negative)

Electrode connected to negative terminal of power

source and work connected to positive terminal

DCEP (d.c. electrode positive) Electrode connected to positive terminal of power source and work connected to negative terminal Switch changes to either electrode positive or electrode

negative

Advantages of a.c. Power Sources

Reduces tendency to arc blow Can use larger electrodes Resulting in faster speeds on heavy materials Lower cost Decreased power consumption High overall electrical efficiency Noiseless operation Reduced maintenance

Duty Cycle given 10-minute period that Percentage of any

machine can operate at rated current without overheating or breaking down
Rating of 100% means machine can be used at rated

amperage on continuous basis

Required by continuous, automatic machine welding

Rating of 60% means machine can be used at its

capacity 6 out of every 10 minutes without damage

Satisfactory for heavy SMAW and GTAW

EFFECT OF CURRENT
Bead width, mm Penetration, mm

Current, A

Current, A

400 A

550 A

700 A

900 A

EFFECT OF VOLTAGE
Bead width, mm Penetration, mm

Voltage, V

Voltage, V

28 V

34 V

38 V

42 V

EFFECT OF WELDING SPEED

Bead width, mm Penetration, mm

Welding speed

Welding speed

400 A

550 A

700 A

900 A

Thank you