MANUFACTURING PROCESSES

Gas Welding

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 OXYFUEL-GAS WELDING PROCESSES
Oxyfuel-gas welding (OFW)refers to a group of
welding processes that use the flame produced
by the combustion of a fuel gas and oxygen as
the source of heat.
Process is popular for small-scale and repair
operations because of its portability, versatility
(most ferrous and nonferrous metals can be
welded), and the low capital investment
required.
Acetylene is the principal fuel gas.
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 OXYA CETYLENE WELDING (OAW)
Oxyacetylene welding (OAW) is a fusion-welding
process performed by a high-temperature flame
from combustion of acetylene and oxygen.
The flame is directed by a welding torch.
A filler metal is sometimes added, and pressure
is occasionally applied in OAW between the
contacting part surfaces.

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 OXY ACETYLENE WELDING (OAW)
Produces a temperature of about 3480C in a
two-stage reaction.
In the first stage, the supplied oxygen and
acetylene react to produce carbon monoxide
and hydrogen

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 OXYA CETYLENE WELDING (OAW)
This reaction occurs near the tip of the torch and
generates intense heat.
The second stage of the reaction involves the
combustion of the CO and H2 and occurs just be-
yond the first combustion zone.

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 OXYA CETYLENE WELDING (OAW)
The oxygen for these secondary reactions is
generally obtained from the surrounding
atmosphere.

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 OXYA CETYLENE WELDING (OAW)
When filler metal is used, it is typically in the
form of a rod with diameters ranging from 1.6 to
9.5 mm .
Composition of the filler must be similar to that
of the base metals.
The filler is often coated with a flux that helps to
clean the surfaces and prevent oxidation, thus
creating a better weld joint.

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 Two Stages Of Combustion
The two stages of combustion are visible in the
oxyacetylene flame emitted from the torch.
Hottest part of the flame
Second Stage

****

First Stage

****[visible only in Carburising flame] 8

 Two Stages Of Combustion
The first-stage reaction is seen as the inner cone
of the flame (which is bright white), while the
second-stage reaction is exhibited by the outer
envelope (which is nearly colourless but with
tinges ranging from blue to orange).
During welding, the outer envelope spreads out
and covers the work surfaces being joined, thus
shielding them from the surrounding
atmosphere.
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 THREE TYPES OF FLAME
Three different types of flames can be obtained
by varying the Oxygen : Acetylene (or oxygen
: fuel gas) ratio.
1. Neutral flame ( 1.0 : 1.0 ) - (1.15 : 1.0)
2. Reducing flame ( 0.9 : 1.0 )
3. Oxidising flame ( 1.5 : 1.0 )

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 REDUCING/CARBURISING
The reducing flame (also called carburising
flame) will have unburned carbon which may be
added to the weld during welding.
Carbursing flame may be fit for welding high
carbon steel or for carburising the surface of low
carbon or mild steel.
This flame is clearly distinguished by a small
feather of acetylene at the end of the primary
zone.
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CARBURISING

Temperature: 3150C

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 OXIDISING
In oxidising flame the inner zone becomes very
small and a loud noise will be induced.
Oxidising flame gives the highest temperature
possible.
Oxidising flame will introduce oxygen into the
weld metal and so not preferred for steel.
A slightly oxidising flame is used for welding
copper base alloys, zinc base alloys, cast irons
and manganese steels.
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 OXIDISING

Temperature: 3480C
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 NETURAL
If the Oxygen : Acetylene ratio is between 1:1
and 1.15:1, all reactions are carried to
completion and a neutral flame is produced.
Most welding is done with a neutral flame, since
it will have the least chemical effect on the
heated metal.
As shown in Figure, this flame has a brilliant
white cone surrounded by a clear blue outer
flame.
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 NETURAL

Temperature: 3250C
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 FLUXES
To promote the formation of a better bond, fluxes
may be used to clean the surfaces and remove
contaminating oxide.
In addition, the gaseous shield produced by
vaporizing flux can prevent further oxidation during
the welding process, and the slag produced by
solidifying flux can protect the weld pool as it cools.
Flux can be added as a powder, the welding rod can
be dipped in a flux paste, or the rods can be pre-
coated.
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 Alternative Gases for OFW
Methylacetylene-Propadiene (MAPP)
Hydrogen
Propylene
Propane
Natural Gas

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 ADVANTAGES
The OFW processes can produce good-quality
welds if proper caution is exercised.
Welding can be performed in all positions, the
temperature of the work can be easily
controlled, and the puddle is visible to the
welder.
Oxyfuel equipment is quite portable, relatively
inexpensive, and extremely versatile.

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 ADVANTAGES
A single set of equipment can be used for
welding, brazing, and soldering, and as a heat
source for bending, forming, straightening, and
hardening.
With the modifications, it can also perform
flame cutting

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 DISADVANTAGES
Exposure of the heated and molten metal to the
various gases in the flame and atmosphere
makes it difficult to prevent contamination.
Since the heat source is not concentrated,
heating is rather slow.
A large volume of metal is heated, and distortion
is likely to occur.
The thickness of the material being joined is
usually less than 6.5 mm .
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 DISADVANTAGES
The combination of acetylene and oxygen is
highly flammable, and the environment in which
OAW is performed is therefore hazardous.

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Process Summary

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 Welding BRASS
Brass, an alloy of copper and zinc.
It is a difficult metal to weld as copper and zinc
have very different melting points (zincs is much
lower).
A strong oxidizing flame is used to weld brass
because it develops a coating on the brass metal
which ensures that zinc fumes are not released
from the brass.
Having too much oxygen, however, will make
welding highly difficult.
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 Welding for Surface Hardness
Carburizing is a heat treatment process which adds
carbon to iron or steel in particular by heating them
in the presence of carbon thereby increasing their
surface hardness from two to six times.
Carburizing flame produced in Oxy-Acetylene may
add carbon to the weld metal and will tend to
remove the oxygen from iron oxides which may be
present, a fact which has caused the flame to be
known as a reducing flame.
Therefore carburising flame increases the surface
hardness of the weld.
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 Flame/Gas/Oxygen/Oxy-Acetylene Cutting

In flame cutting, the cutting torch with its high

flame temperature of 3100 C is used to heat the
steel to its kindling temperature (ignition
temperature) and then by introducing a stream
of pure oxygen, to create a rapid oxidation of the
steel (the steel catches fire and burns to become
a slag).

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 Flame/Gas/Oxygen/Oxy-Acetylene Cutting

The oxygen cutting process can be considered as

a combination of two distinct and separate
processes.
1. First the material to be cut must have its
temperature increased to the point where it will
burn in the presence of oxygen. This is called
the ignition temperature of the steel. In oxygen
cutting of steel this is achieved by pre-heating a
localised area until the metal reaches a bright
cherry red heat at about 870900C.
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 Flame/Gas/Oxygen/Oxy-Acetylene Cutting

2. At this point a jet of cold oxygen(room

temperature) at high pressure is passed through
the centre of the nozzle onto the red-hot steel.
This causes a chemical reaction between the
steel and the oxygen, generating more heat,
melting the steel. This is called an exothermic
reaction.

NOTE:- Steel melts at 1535C but can be ignited at

884C.
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 Flame/Gas/Oxygen/Oxy-Acetylene Cutting

The steel immediately below the oxygen jet is

converted to a metal oxide or slag, and is blown
away by the jet.
This process is referred to as a chemical process.
If the oxygen stream isnt powerful enough, or the
cutting speed is too quick, the slag will solidify in
the cut, and a cut will not be achieved.
As the torch begins to move, more steel is
preheated and the oxygen jet burns more of the
steel, creating the cut.
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Flame/Gas/Oxygen/Oxy-Acetylene Cutting

Direction of Cut

Pre-Heating
Flame

Cutting Oxygen 30
Flame/Gas/Oxygen/Oxy-Acetylene Cutting

Welding tip Cutting tip

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Chemistry of Oxygen Cutting

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 Functions of the preheat flames
1. Raise the temperature of the steel to the
ignition point,
2. Add heat energy to the work to maintain the
cutting reaction,
3. Provide a protective shield between the cutting
oxygen stream and the atmosphere, and
4. Dislodge from the upper surface of the steel any
rust, scale, paint, or other foreign substance
that would stop or retard the normal forward
progress of the cutting action.
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