HOT AND COLD METAL WORK

8609-A

OXYFUEL CUTTING AND WELDING

OXYFUEL CUTTING AND WELDING
The term oxyfuel* refers to the process of combining pure oxygen with a combustible fuel gas to produce a
flame. The oxyfuel process can be used for welding, brazing, cutting, and heating metals. Oxygen and fuel
gases are stored under pressure in cylinders, and are released as individual gases through valves, regulators,
and hoses. These gases are mixed as they flow through torch assemblies and burn as they are discharged
through special tips.
Fuel gases available include: propane, natural gas, propylene, and acetylene. Fuel gases vary in their chemical
composition, and interact with the metal in different ways. Selecting the right gas for cutting or welding
depends on a variety of factors. Some factors to consider are:

Availability and cost of fuel gasses

Welding process or operation to be performed
Thickness of metal and type of welded joint to be produced
Physical properties of metals
Chemical properties of metals

Propane (C3H) is supplied in a liquid form under positive pressure, which varies with temperature. Most
oxyfuel cutting torches can use LP gas, but special hoses and cutting tips are required. Propane is readily
available in most areas. For the most effective and efficient use of propane as a cutting fuel, specially
designed and manufactured torches should be purchased. Due to cost, propane cutting is heavily used in the
metal recycling industry.
Propylene (C3H6) is a fuel gas that has been used for approximately 30 years. It is stable in both liquid and
gas states, economical, produces little slag, and has a high heat value. This heat value is due to the fact that
the molecules in propylene are united in a double carbon bond. Breaking down this double bond produces
more heat. Propylene does not have the withdrawal pressure limitations that are necessary with acetylene.
According to MSDS information, the propylene used for oxyfuel cutting is approximately 5% propylene,
87% propane, and traces of other gasses.
Acetylene (C2H2) is the most widely used fuel gas for welding and cutting applications. It produces a clean
weld and a controllable flame. It is less stable and more expensive than other fuel gases. However, since it
performs most functions well and is widely available, it is the most commonly used fuel gas for most agricultural
mechanics laboratories and service centers.

* Underlined words are defined in the Glossary of Terms.

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Compressed natural gas (CH4) is adaptable for cutting, soldering, brazing, and preheating. A water seal or
blowback valve to prevent backfiring into the gas supply line must protect the natural gas source.
Physical and Chemical Properties of Oxyfuel Gasses
Factor
Specific gravity
o

Propylene

Acetylene

Propane

Natural Gas

1.49

0.906

1.52

0.62

Boiling point ( F)

-54

-8.4

-50

-161

Neutral flame
o
temperature ( F)

5340

5700

4700

4500

Heat emission of
primary flame
3
(BTU per ft )

434

507

255

12

Secondary flame
o
temperature ( F)

1938

963

2240

990

2372

1470

2495

1000

21,600

21,500

21,600

23,600

Cutting, heating,
stress relieving,
brazing, soldering

Cutting, heating,
stress relieving,
brazing, soldering

Cutting

Production cutting

BTU per ft

Total heating
value (BTU per lb)
Common uses

FACTS ABOUT OXYGEN AND ACETYLENE

Oxygen (O2) is colorless, odorless, tasteless, and is heavier than air. Oxygen makes up about 20% of the
atmosphere. Oxygen itself will not burn, but when mixed with combustible materials it becomes highly explosive.
Oxygen is produced commercially by causing air to liquefy and using fractional distillation to recover the oxygen.
Oxygen is generally compressed into steel cylinders at a pressure of 1,800 to 2,400 pounds per square inch
(psi). Care should be taken in handling these cylinders due to the fact that oxygen supports combustion and is
explosive if handled improperly. Cylinder sizes range from 80 to 244 cubic feet (ft3).
Acetylene gas (C2H2) is colorless, has a very distinct odor, and is highly combustible. Acetylene cylinder
sizes range from 60 to 300 cubic feet. The cylinder contains a porous substance saturated with liquid
acetone. Acetylene is pumped into the cylinder, displacing some of the acetone. Acetylene is not under
extremely high pressure; a full cylinder is pressurized to approximately 250 psi. However, acetylene may
NOT be withdrawn at a rate higher than 15 psi.
FUNCTIONS OF OXYFUEL HEAT
Oxyfuel cutting of mild carbon steel heats the metal to kindling temperature (1,400F to 1,800F), then
oxidizes and blows the slag from the cut with a stream of pure oxygen.
Oxyfuel welding fuses two pieces of metal by heating them to the melting point with a combustible mixture of
oxygen and fuel gas. This process can be done with or without the use of a welding rod.

The joining of metals by adding bronze filler is known as brazing.

Soft and hard solders (lead and silver alloys) are the filler materials used in soldering.

The oxyfuel flame is also used to bend, shape, preheat, stress relieve, post-heat, and temper metals.
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PROCEDURE FOR ASSEMBLY OF THE OXYFUEL RIG

a.

Secure the oxygen and fuel gas

cylinders to a wall, a special cylinder
cart, or a special rack if transported
to job sites in a truck.

b.

Remove the valve protection caps

and wipe off any dirt accumulation
with a clean dry cloth (free from oil
or grease).

c.

Slightly open (crack) both cylinders

to make sure they do not stick and
to blow out any dirt or dust lodged
in the valve. Close the valves.

d.

Check for leaks with mild soapy

water using a clean brush. All
valves, connections, and soft plugs
should be checked.

e.

Attach the regulators to the cylinders so that they point toward the ceiling to prevent someone from
getting in front of the regulator.

f.

The regulators, safety check valves, and hoses should be tightened securely with a wrench.

g.

Do not use a wrench to attach the welding tip or cutting attachment to the torch.

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OXYFUEL EQUIPMENT
Oxyfuel equipment is designed with several built-in safety precautions. Oxygen hoses are usually green; fuel
gas hoses are red. All oxygen connections and cylinders have right-hand threads. All fuel gas connections and
cylinders have left-hand threads. Fuel gas fittings have a V notch cut around the outside of the connectors;
oxygen fittings and connectors are smooth.
a.

Cylinders two.

b.

Regulators two sets, two stage regulators are the safest to use.

c.

Hoses color-coded and specifically designed based on use. Type R fuel gas hoses are designed
specifically for acetylene use, while Type T hoses are approved for all fuel gasses.

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d.

Safety Check Valves two sets recommended, attach between regulators and hoses and between
hoses and torch to prevent reverse flow of the gases and flame (flashback) that could cause hose
fires, regulator ruptures, and cylinder fires.

e.

Torch handle regulated by two valves, often equipped with internal reverse flow check valves.

f.

Cutting attachment regulated by preheat oxygen control valve, operated by depressing the cutting
oxygen lever.

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g.

Cutting tips 3 to 8 preheat orifices and 1 oxygen-cutting orifice. Drill size determines tip size. The
propane tip is a 2-piece tip with at least 6 preheat orifices.

h.

Welding tip 1 orifice for gas mixture; the size is determined by drill size of orifice.

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i.

Miscellaneous tip cleaner, spark lighter, adjustable locking pliers, wire brushes.

j.

Personal protective equipment for oxyfuel cutting and welding.

-7-

SAFETY PRECAUTIONS FOR OXYFUEL PROCESSES

a.

Keep oil and grease away from all parts of the welding and cutting apparatus.

b.

Secure the cylinders in an upright position so they cannot be overturned.

c.

Face the regulator gauges up toward the ceiling, making it impossible to stand in front of them.

d.

Store and use oxyfuel units in well ventilated areas adequately separated from other activities.

e.

Acetylene pressure in the lines should NEVER exceed 15 pounds per square inch.

f.

Open the acetylene cylinder valve 1/4 to 1/2 turns; if it is the wheel type, open all the way.

g.

Use an approved spark lighter to light the torch; never use matches or cigarette lighters.

h.

NEVER use oxygen to operate pneumatic tools, blow out lines, inflate tires, or dust off clothing.

i.

Never hang clothing on cylinders, running the risk of saturating them with oxygen and acetylene.

j.

Do NOT convert an acetylene regulator to an oxygen regulator or vice versa.

k.

Slowly open the oxygen cylinder valve to prevent a sudden surge of pressure.

l.

Release or loosen the regulator adjusting screw before opening a cylinder valve.

m.

Do not walk with a lighted torch or lay down a lighted torch.

n.

Blow out hoses before attaching the torch.

o.

Repair hoses with proper hose splices, not friction tape. NEVER use a leaking hose.

p.

Test for leaks with soap and water, not matches.

q.

If valves on cylinders are faulty or too tight, notify the supplier; undue force would be dangerous.

r.

Keep a fire extinguisher handy at all times.

s.

Dress properly and wear eye protection.

t.

Prevent heat and sparks from getting to cylinders and hoses.

u.

Do not strike an arc on a cylinder or hit a cylinder with a metal object.

v.

Never use a cylinder as a ground in an electrical circuit.

w.

Never guess; get the correct information from a qualified person.

x.

Mark, isolate, or otherwise designate empty cylinders.

y.

Oxygen and fuel gas cylinders (either full or empty) MUST be stored separately in accordance with
safety and fire codes.
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-9-

SET-UP PROCEDURE FOR OXYFUEL TORCH NOZZLE

1.
2.
3.
4.
5.
6.
7.
8.

Check torch body for closed valves.

Check regulator for loose regulator adjusting screw.
Open acetylene cylinder valve 1/4 - 1/2 turn (wheel-type valves one turn) maximum.
Turn acetylene regulator adjusting screws to desired working pressure.
(remember, about 1 lb. pressure is used to activate the regulator).
Open oxygen cylinder valve completely.
Turn oxygen regulator adjusting screw to desired working pressure.
(In some work applications, oxygen pressure will equal acetylene pressure.)
Crack acetylene torch valve and light the torch, open acetylene torch valve until soot disappears.
Open oxygen torch valve to adjust to neutral flame; no acetylene feather and sharp inner cone.
NEVER exceed a pressure of 15 psi with acetylene. The oxygen pressure can be 3 to 10 times
higher than the acetylene pressure when cutting. When welding, the ratio of oxygen to acetylene is
approximately 1:1. Oxygen and acetylene settings will vary depending on the attachment tip and
thickness of metal to cut or weld.

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SHUTDOWN PROCEDURE FOR OXY-ACETYLENE TORCH NOZZLE

1.

Turn off acetylene valve on torch butt (the flame goes out) NEVER turn off oxygen first.

2.

Turn off oxygen valve on torch butt.

3.

Close acetylene cylinder valve.

4.

Bleed acetylene hose by opening acetylene torch valve (both gauges drop to 0), close valve.

5.

Back acetylene regulator adjusting screw until loose.

6.

Close oxygen cylinder valve.

7.

Bleed oxygen hose by opening oxygen torch valve (both gauges drop to 0), close valve.

8.

Back oxygen regulator adjusting screw until loose.

9.

Recheck valves for closure, roll up hoses. If rig is not to be used for some time, remove the regulators
and put the safety caps back on the cylinders.

10. NEVER leave equipment under pressure 24 hours a day, close equipment daily.
CUTTING METALS
The metal to be cut should be clean, marked with a punch or soapstone, and placed in a suitable position for
cutting. To prevent damage where hot metal falls, do not cut over a concrete floor. Use a container or
special cutting table device to catch the molten metal. Hot metal can also damage hoses and cause fires.
Oxyfuel cutting is limited to ferrous metals such as carbon steels, alloy steels, low chromium steels, and
manganese steels. Steels with a high tungsten or chromium content or stainless steel cannot be cut with
oxyfuel. Cast iron is more difficult to cut than steel; therefore, an excess fuel flame is used. More oxygen
pressure is needed due to the fact that more heat is required for cast iron. The cutting tip is held at 45
degrees to start the cut and raised to 75 degrees to make the cut.
The steps to follow in making a cut are:
1.

Hold the blowpipe perpendicular to the surface of the metal unless bevels are to be cut. Hold the
flame inner cone about 1/16 to 1/8 inch above the plate. The proper distance away from the plate will
prevent metal from sticking to the tip. Hold the tip so that two preheat holes are in line with the cut
(one leading the cut, and the other following the cut).

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- 12 -

2.

Hold the torch at the edge of the metal until the metal begins to melt. The top of the torch may be
slanted toward the cut and changed to a vertical position as the cut progresses.

3.

Press down slowly on the cutting oxygen lever until the cutting valve is completely open. When the
cut is through the metal, move the torch along the mark.

4.

Tilt the torch tip toward the direction of cut on thin metal. It should be held in a vertical position on
thick metal.

5.

Move the torch slowly along the surface or the oxygen stream will not pass completely through thick
metal. To restart the cut, release the cutting lever and reheat the metal again before pressing the
cutting lever. Losing the cut may cause irregular edges.

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6.

When beveling plate edges or cutting at an angle, lean the tip at the desired angle and hold the torch
parallel to the work.

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Steps to follow when piercing holes are:

1.
2.
3.
4.

5.

Hold the blowpipe tip perpendicular to the surface until a spot on the surface begins to melt.
Raise the torch until the tip is about 1/2 inch from the surface and slowly press the lever as the torch
is raised.
Move the tip to one side of the heated area so that the slag can be blown out.
Move the inner cone within about 1/8 inch from the surface and make the cut on the inside edge of
the hole.

To facilitate the cutting of a hole in thick metal, drill a hole 1/4 in diameter or larger and start the
piercing in this hole.

CARE OF OXYFUEL TIPS

Tips frequently become spattered with metal or other materials that may cause inferior work. Tips are
cleaned in the following manner:
1.
2.
3.
4.

The tip point can be cleaned and squared by rubbing with emery cloth, steel wool, or the file on a
tip cleaner.
Insert the correct size cleaner into each orifice. Push in and pull out; do not twist or bend the cleaner.
Open oxygen slightly during this procedure to blow out foreign particles.
Care should be taken not to damage the threads and seats of the tips.

PREPARING METAL FOR WELDING

a.

Free the metal from oil, paint, grease, dirt, rust, and other foreign material. Heat the metal with the
torch, and then clean with a wire brush.
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b.

Thick metal should be beveled with a grinder or the torch.

c.

Align the plates to be welded and tack weld them to prevent warping.

PROPER WELDING TIP POSITIONS

a.

The blowpipe can be held like a hammer when standing or like a pencil when working in the sitting
position.

b.

The tip should be held at a 45-degree angle to the work surface. The welding rod should also be held
at a 45-degree angle to the surface and in line with the weld.

c.

The inner cone flame should be 1/16 to 1/8 inch above the metal.

d.

Preheating the metal is very important in making a successful weld; therefore, the flame should be
moved in the direction of the weld, and the cone should stay inside the puddle.

OXYFUEL WELDING PROCEDURES

One of the most important steps in learning to weld with oxyfuel is to carry a molten puddle of metal along the
line or seam of parts to be joined. Forming the puddle and running the bead include the following practices:
The flame is held at the starting point until a bright round pool (1/4 to 3/8 inches in diameter) is formed. The
motion of the tip and penetration control the width of the puddle. Welding speed should be adapted to
maintain a uniform puddle width. The inner cone is held 1/16 to 1/8 inch above the surface. If the speed is too
slow, the flame will burn a hole through the metal or form a large puddle. If the speed is too fast, the bead will
be irregular and narrow.

The most common movement pattern for fusion welding is the circular motion. The zigzag motion is best
when using a filler rod.
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When using either pattern, the torch should be held at about 45 degrees to the surface. The welding rod
should be held at 45 degrees, but slanted away from the torch tip. The rod diameter should be equal to the
thickness of the metal. The torch may be held so the tip is pointed in the direction of the weld (forehand
welding) or the tip pointed toward the weld (backhand welding).

TYPES OF WELDED JOINTS

Most welded joints are either butt joints or fillet joints. When two pieces of metal are butted together and
welded, with or without beveling, the term used for this practice is butt-welding.
If the metal pieces are joined together forming an angle, this is known as fillet welding.
WELDING CAST IRON AND HARDSURFACING
Welding cast iron is generally done with a bronze rod, unless the color of the base metal must be matched.
Cast iron rods require higher preheating than bronze rods.
1.

Practice procedure for welding cast iron

a. Select the correct flux.
b. Clean and bevel the edges of the stock.
c. Use a 3/16-inch rod with a neutral flame and tack the ends together.
d. Heat the rod tip to a red-colored heat and dip it in the flux, then dip the tip into the molten
puddle of cast iron. Pool heat will melt the rod.
e. Weld in the same manner as fusion welding on mild steel. Dip the hot tip of the rod in flux from
time to time. If bubbles appear, add more flux. Flux promotes fusion and prevents an oxide
coating on the weld.

2.

Practice procedure for braze welding

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The main advantage to braze welding is that it does not require an extremely high welding temperature that
may change the malleable properties of the metal.
a.
b.
c.
d.
e.

Clean the surface to be welded.

Bevel and align edges of the metal.
Use neutral flame and heat the end of the rod and dip into the flux.
Heat the area to be welded to a dull red and tack ends.
Apply flux from rod on heated area, then pass rod into flame and deposit a small amount of bronze at
intervals until the weld is complete. Add flux from time to time.

Hardsurfacing practice procedure:

1.

Hardsurfacing is the application of an all alloy material to another metal for the purpose of reducing
wear. Metals subjected to abrasive wear, such as cultivator sweeps and bucket or digger teeth, can
be hardsurfaced.

2.

The procedure for hardsurfacing is as follows:

a. Thoroughly clean the metal before applying alloy.
b. Place the material to be hardsurfaced in a flat position.
c. Heat a small section of the area with an excessive acetylene flame until the metal begins to sweat.
d. Touch the tips of the alloy rod to the surface and melt enough of the rod to form an alloy cover
1
/16 inch thick and a desirable width without heating the base metal to a melting point.
e. Maintain the hardsurfacing temperature in front of the path on the hard metal. Add just enough
rod to the metal to maintain a uniform thickness and width.
f.
Hardsurfaced metal should be allowed to cool slowly. Dry lime serves as a good cover for
cooling metal.
g. Be sure to follow recommendations of the manufacturer of the hardsurfacing rods. A special
sweat-on paste may be applied with a brush and fused with the oxyfuel heat using a slightly
carburizing flame.

AMERICAN WELDING SOCIETY CERTIFICATION

The AWS, or American Welding Society, is the professional organization responsible for setting standards for
the certification of weldors. The first step in becoming a highly skilled craftsman is to certify as an Entry
Level Weldor. The certification process for Entry Level Weldor consists of two components, a practical
knowledge test and a performance test. The practical knowledge test covers subjects such as welding/
cutting theory, welding/cutting inspection and testing, skill-related vocabulary, metal identification, welding
variables, electrical fundamentals, welding symbol interpretation, fabrication principles and practices, and
safety. The practical knowledge test requires a minimum passing grade of 75%, with a minimum score of
90% on the safety-related questions.
The performance test requires an entry-level weldor to demonstrate skill in reading welding symbols, following
written procedures, cutting parts to proper specifications, fitting parts correctly, and performing specific
welding techniques. These tests require that the candidate prepare their test coupon by oxyfuel (OFC) and
plasma-arc cutting (PAC). This preparation includes both cutting straight lines and piercing holes

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(For additional information about oxyfuel cutting and welding, refer to IMS video #9784 Oxyacetylene
Welding: Safety and Introduction, #9785 Oxyacetylene Welding and Brazing, #9786 Oxyacetylene Cutting,
and #9787 Acetylene Cylinder Safety.)
(For oxyfuel cutting and welding activities related to your SAEP, refer to IMS #RB-221, Activities for
Agricultural Science 221. After completing an activity, be sure to record the entry in the journal page of your
Internet record book, and click on 221-E for the Course and Unit of Instruction.)

A SLEEPING GIANT
I am a compressed gas cylinder.
I weigh in at 175 pounds when filled.
I am pressurized at 2,200 pounds psi.
I have a wall thickness of about 0.25
I stand 57 inches off the deck.
I am 9 inches in diameter.
I wear a cap when not in use.
I wear valves, gauges, and hoses when at work.
I wear many colors and bands to tell what tasks I perform.
I transform miscellaneous stacks of materials into glistening
ships -- when properly used
I transform glistening ships into miscellaneous stacks of material
when allowed to unleash my fury unchecked.
I am ruthless and deadly in the hands of anyone careless or
uninformed.
I am too frequently left standing alone on my small base -- my
cap removed & lost by an unthinking workman.
I am ready to be toppled over -- where my unprotected valve can
be snapped off -- and all of my power unleashed through
an opening no larger than a #2 pencil.
I am proud of my capabilities - here are a few:
I have been known to jet away faster than any AA fuel
dragster on the NHRA circuit - over 800 mph;
I smash my way through brick walls with the greatest of
ease;
I fly through the air for distances of more than half a mile;
I spin, ricochet, crash, and slash through anything in my
path;
I scoff at the puny efforts of human flesh, bone, and muscle
to alter my erratic course;
I can penetrate a pickup truck from end to end;
I have been known to blast my way through four 14-inch
brick walls before running out of pressure.
My escaping oxygen exhaust burns everything in its path.
I can, under certain conditions, rupture or explode -- then,
you read about my exploits in the newspaper.
You can be my master ONLY under my terms:
Full or Empty, be sure my cap is on straight and snug;
Never, NEVER leave me standing alone;
Keep me in a secure rack or tied so that I cannot fall;
Treat Me With Respect, I am A SLEEPING GIANT

Courtesy of Mr. Charlie Yeates (deceased), Oxyacetylene

Specialist, Adult Specialist Program

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Checking for Oxyacetylene Cylinder Leaks

The standard acetylene cylinder contains from 90 to 154 ft3, stored in a porous filler saturated with acetone.
These cylinders are filled under pressure, and may develop leaks around the valve stem or in the soft plugs.
Any acetylene cylinder is a fire hazard, but a cylinder leaking for an entire weekend into a closed facility can
become a tragedy of significant proportions. Sparks from electrical switches or pilot lights on forced-air
heaters can provide the necessary ignition source.
To guard against fire damage, a good practice is to check acetylene cylinders for leaks when delivered. This
is a relatively simple process.
Materials Needed:
1.
2.
3.

small paintbrush
one-quart container
one pint liquid soap, or a soap and water solution

Procedure:
1.

Lay acetylene cylinder on its side and paint the soft plugs with the soap solution. A leak here will
cause bubbles to form.

2.

Stand the cylinder upright and paint the soft plugs on the shoulders of the bottle. DO NOT try to stop
leaks in or around soft plugs - call the dealer and have the cylinder replaced!!

3.

Paint the regulator receptacle or main opening before attaching the regulator. If the bottle shows a
leak now, this means that the main valve seat is damaged and leaking, regardless of how tightly the
cylinder valve is closed.

4.

Paint the main valve stem around the ring nut at the top of the valve. If a leak is present here, stop the
leak by tightening the ring nut with an adjustable wrench.

5.

Attach the regulator to the cylinder and open the cylinder valve; paint the regulator ring nut and
repaint the cylinder valve stem. Sometimes a cylinder may not leak at the cylinder valve stem until
after the regulator is attached and the valve is opened.

6.

Ask the distributor that any leaking bottles be replaced at their cost.

NOTE: Oxygen cylinders can be checked in the same manner EXCEPT:

A commercial leak detector liquid such as Snoop should be used (Best idea), OR
A non-petroleum based liquid detergent must be used (such as Ivory liquid).
Remember, oxygen cylinders are pressurized to about 2,200 lbs. psi.

- 20 -

SELECTED STUDENT ACTIVITIES

FILL IN THE BLANK: Complete the following statements using the correct word or phrase.
1.
2.
3.
4.

_______________________ is colorless, odorless, tasteless, and will support combustion.

Full cylinder pressure for oxygen is ______________ to _____________ pounds psi.
Full cylinder pressure for acetylene is approximately _____________ pounds psi.
The end of the inner cone may produce a neutral flame temperature from about ______ to ______
degrees F.
5. Besides cutting and welding, the oxyfuel flame is used to _______________, ______________,
______________, ________________, and _______________ ______________.
6. Check for leaks with mild ________________ _________________ and a paintbrush.
7. The regulator adjustment pressure for oxygen and acetylene will vary depending on the
_________________ size and _________________ thickness.
8. A __________________ flame has a rounded inner cone, quiet sound, and an equal mixture of
oxygen and acetylene.
9. While cutting and welding, the tip of the inner cone should be held ________ to ________ inch
above the metal.
10. Tip size is determined by the drill size of the ______________________________.
11. Acetylene must not be withdrawn from the cylinder at a rate greater than _____________ psi.
TRUE/FALSE: Circle the T if the statement is true or F if it is false.
T
T
T

F
F
F

T
T
T
T
T
T
T

F
F
F
F
F
F
F

T
T
T
T
T
T

F
F
F
F
F
F

12. Oxyfuel rigs can weld only thin metal.

13. Oxygen cylinders are equipped with double-seated valves and should be opened all the way.
14. Acetylene cylinders not having the wheel type valve opener should be opened less than
one turn.
15. Pressure in the acetylene hose line should never exceed 15 pounds psi.
16. Open the regulator valve prior to opening the high-pressure valve on the oxygen cylinder.
17. Goggles need not be worn when working with oxyfuel.
18. Matches may be used for lighting the torch.
19. An oily wipe cloth should be used to clean out the oxygen cylinder fittings.
20. Always bleed hoses and loosen regulator valve screws when work is completed.
21. In fillet welding, overheating may be avoided by frequently dipping the torch into a bucket
of water.
22. In brazing, or bronze welding, a flux must be used.
23. In hardsurfacing, a carburizing flame is used.
24. In cutting, a neutral flame is used.
25. Cutting metal should be done over concrete floors.
26. Stand in front of gauges while opening cylinders.
27. It is safe to run two oxyfuel flame-heating tips off the same acetylene cylinder if the tips only
consume 10 lbs. psi each of acetylene.
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DISCUSSION: Following demonstration by your instructor, briefly discuss and complete the following activities.
28. Assemble the oxyfuel rig.
29. Turn on and adjust the oxyfuel rig.
30. Complete the shutdown of the oxyfuel rig.
SKILL PERFORMANCE ACTIVITIES: Following completion of this topic, practice the following skills
as assigned by your instructor.
31. Cutting with Oxyfuel
1.
2.
3.

Materials: Mild steel plate (1/4, 3/8, 1/2, 3/4, and 1 inch thick) and 2-inch pipe.
Objective: Cut and Pierce Plate; Cut Pipe
Procedure:
a. Clean the metal and mark the line to be cut.
b. Properly position the metal so that molten metal and sparks will fall into a container.
c. Select the correct tip and properly align the orifices.
d. Set the pressure and adjust to a neutral flame.
e. The cut can be made free hand or with a guide.
f.
Tilt or angle the torch depending on the thickness of the metal.
g. Cut in a straight line.
h. Cut a semicircle.
i.
Cut a circle.
j.
Pierce a 1/2-inch hole.
k. Cut a 90-degree angle on 2-inch pipe.
l.
Cut a saddle on 2-inch pipe.

32. Welding and Brazing with Oxyfuel

Part 1:
1. Material: 14-gauge sheet steel, 4 x 6 inches
2. Objective: Form and Run a Puddle
3. Procedure:
a. Adjust flame to neutral at the desired temperature.
b. Produce a live puddle (1/4 - 3/8 inches in diameter).
c. Hold the tip at a 45-degree angle to the metal pointed in the direction of travel.
d. Using the oscillating motion, move the puddle in a straight line at the proper speed.
e. Examine the result for uniformity.
Part 2:
1. Material: 14-gauge sheet steel, 2 pieces - 4 x 6 inches
2. Objective: Fusion Welding Without a Rod
3. Procedure:
a. Position the two pieces of metal at a right angle and tack weld the ends with a neutral flame.
b. A corner fillet joint will be formed.
c. Establish a live puddle.
d. Using the neutral flame pointed in the direction of travel, begin oscillating the tip.
e. Move at a speed that allows the puddle to properly advance.
f.
Examine for flaws and uniformity.
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Part 3:
1. Materials: 1/4-inch mild steel plate and mild steel welding rods (copper coated to prevent rusting
while in storage)
2. Objective: Fusion Welding With Filler Rod
3. Procedure:
a. Position metal joint and adjust torch flame to neutral.
b. Produce a live puddle.
c. Insert end of rod into the center of the puddle directly under the blue inner cone and proceed to
build a bead by oscillating both the rod and the torch, which are held at 45-degree angles to the
surface, and move forward at an even speed.
d. Keep the tip of the blue inner-cone at least 1/8 inch above the surface of the live puddle.
e. Examine for uniformity.
Part 4:
1. Materials: 1/4-inch mild steel plate; brazing rods; and general-purpose flux
2. Objective: Braze Welding With Filler Rod
3. Procedure:
a. Clean and position the metal.
b. Set torch to a neutral flame.
c. Heat the end of the rod and dip it into the flux until it is well coated.
d. Bring surface of steel to a cherry red heat (no puddle when brazing).
e. Braze the joint with brass by laying a thin coat of brass along the entire joint.
f.
Cut the flame down to 1/2 the original temperature and proceed to build up the bead with no flux
on second and/or third pass.
g. Examine for uniformity.
NOTE: Brazing cast iron uses the same technique as mild steel except a special flux must be used.
NOTE: Welding cast iron differs from welding mild steel in that a cast iron rod must be used with a special
flux. Allow the weld to cool slowly.
Acknowledgements
Praxair Distribution, Inc., provided valuable technical assistance in the revision of this topic.
Kirk Edney, Curriculum Specialist, Instructional Materials Service,
Texas A&M University, revised and edited this topic.
Vickie Marriott, Office Software Associate, Instructional Materials Service,
Texas A&M University, prepared the layout and design for this topic.
Christine Stetter, Artist, Instructional Materials Service,
Texas A&M University, prepared the illustrations for this topic.

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REFERENCES
FG2 High Technology Fuel and Cutting Equipment (brochure). Norcross, GA: Praxair/Chemweld, Inc.
Griffin, Ivan H., and Edward M. Roden. Welding Processes. Albany, NY: Delmar Publishers, Inc.
Herren, Ray and Cooper Elmer L. Agricultural Mechanics: Fundamentals and Applications. 4th ed.
Albany, NY: Delmar Publishers, Inc.
Morford, V. J., et al. Metals and Welding in Agriculture. Hobar St. Paul, MN: Publications, Inc.
Oxyfuel Cutting, Module 29101: Instructors Guide for AWS Entry Level Welder. National Center for
Construction Education and Research. Upper Saddle River, NJ: Prentice Hall Publishers, 2000.
Oxy-Gas Cutting. Materials Engineering (UK) Ltd. Derby, England, UK [May 27, 2002.] [On-line].
Available: http://www.meg.co.uk/ 1997
Safety in Welding, Cutting, and Allied Processes, ANSI Z49.1: 1999. Miami, FL: American Welding Society.
The Oxy-Acetylene Handbook. New York City, NY: Union Carbide Corporation - Linde Division.
Welding, Cutting, and Heating Guide. Denton, TX: Victor Welding and Cutting Division.
GLOSSARY OF TERMS
Brazing The joining of metals by adding bronze filler.
Coupon The metal plate prepared by weldors in the performance section of the AWS certification test.
Flashback When the oxyfuel mixture burns inside the torch handle.
Hardsurfacing The application of an all alloy material to another metal for the purpose of reducing wear.
MSDS Material safety data sheets.
Oxyfuel process The combination of pure oxygen and a combustible fuel gas to produce a flame.
Soldering The joining of metals by using lead and silver alloys as filler materials.
ADVANCED ACTIVITIES
1.

2.
3.
4.

Go to the Materials Engineering Group Web site and take the Oxy-Gas cutting test several times over
the course of this unit. Report your score to your teacher. Make a chart that documents your score
improvement.
Obtain some reject horseshoes from a local farrier. Practice your hardsurfacing technique on the toes
of the horseshoes.
Research the topic Nondestructive Testing. Report your findings to your agricultural science class.
Research and develop a presentation focused on the molecules involved in oxyfuel processes. Include
chemical formulas and molecular representations of the elements and compounds involved.
ALL RIGHTS RESERVED
Reproduction prohibited without written permission.
Instructional Materials Service
Texas A&M University
2588 TAMUS
College Station, Texas 77843-2588
http://www-ims.tamu.edu
2002
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