GAS WELDING COMPONENTS

Oxyacetylene
welding is very
versatile and
almost all metals
and their alloys can
be welded with it.

Typical Oxyacetylene Welding

(OAW) Station

Oxygen Cylinders
Oxygen
cylinders
are made of
solid drawn
steel and
designed to
hold
compressed
oxygen at
high
pressure for
industrial

An oxygen
cylinder
has a righthand
regulator
connection
thread and
is painted
black

It has a
bursting disc
fitted, which
will blow out
and let the
oxygen
escape if the
cylinder
pressure
becomes to
great, such
as in a fire.

Acetylene Cylinders
Acetylene
cylinders
contain a
porous
material
saturated
with acetone
in which
acetylene
gas was
dissolved.

 Cylinders are filled

with a very porous
substance monolithic
filler to help prevent
large pockets of pure
acetylene form
forming
Cylinders have safety
(Fuse) plugs in the top
and bottom designed
to melt at 212 F (100
C)

This is similar to the

way carbon dioxide
is dissolved in
lemonade. As a
gas, acetylene is
unstable and can
self detonate it is
compressed
beyond 175 Kpa.

As the pressure is
increased, more
acetylene will be
dissolved: for
example, one (1)
volume of acetone
will absorb 25
volume of
acetylene at
atmospheric
pressure; but, at 15
atmospheres
pressure, 375
volumes may be
dissolved.

To assist in even distribution of

acetylene in the acetone, the bottle
also contains kapok fibre, which
gives a cellular construction to the
chamber. The cellular construction
also prevents too rapid discharge of
gas.

Acetylene Valves
Acetylene cylinder shut
off valves should only
be opened 1/4 to 1/2
turn
This will allow the
cylinder to be closed
quickly in case of fire.
Cylinder valve
wrenches should be left
in place on cylinders
that do not have a
hand wheel.

Regulator Pressure Settings

The maximum safe working pressure
for acetylene is 15 PSI !

Acetylene cylinders
have a left-hand
regulator
connection thread
and are painted
crimson.

Fusible plugs are

fitted to the top of
the cylinder and in
the event of a fire,
this melt at 100C
and allow the gas
to escape.

When working with

acetylene cylinder you
must consider the
following:
Dont pass acetylene
through copper fittings
pipes. This will form
copper acetylene,
which is a substance
capable of self
detonation.

Never set acetylene

regulator pressure
above 100 Kpa.
To prevent drawing
out acetone with
the acetylene gas,
restrict the draw-off
rate to 1/7 of the
cylinders content
per hour.

Regulators
Regulators are
needed to
reduce and
control the
flow of gases
from the
cylinders.
Oxygen
regulators
are coloured
black and
acetylene
crimson.

Regulators allow;
The contents of the
cylinder to be
monitored.
The reduction of
cylinder pressure to a
safe working
pressure.
A constant working
pressure to be set
and adjusted.

Pressure Regulators safety Tips.

Inspect all nuts and
connections before
use to detect faulty
seats that may
cause leakage of
gas.

Before opening the valve of

a cylinder to which a
regulator has been
attached, be sure that the
pressure-adjusting screw
has been completely
released by turning it to the
left. Failure to do this allows
the full cylinder pressure to
hit the engage mechanism
of the regulator. Not only
will the regulator be
damaged, but it may also
burst and injure the welder.

 Never attempt to
connect an
acetylene regulator
to a cylinder
containing oxygen
or vice versa. Do
not force
connections that
do not fit, and be
sure that all
connections are
tight.

Use regulators only

for the gas and
pressure for which
they are intended.

 Have regulators repaired only by

skilled mechanics who have been
properly trained.

Hoses and Connectors

Reinforced rubber hoses and brass fittings
are used to transport the gases from the
cylinders to the handpiece handle. Hoses are
black with right hand fitting for oxygen and
crimson with left-hand fitting for acetylene.

Care of Hose
Always use a hose
to carry only one
kind of gas. A
combustible
mixture may result
if it is used for first
one gas and then
the other.

 Test the hose for leaks frequently by

immersing the hose at normal working
pressure under water. A leaking hose is a
serious hazard and a waste of gas. If there
is a leak in the connection with the proper
nipple and nut, cut off the hose a few
inches back and remake the connection.
Leaks in other locations should be
repaired by cutting off the bad section and
inserting a hose coupling as a splice.

 Clamp all of the

hose connections
or fasten them
securely so that
they will withstand
pressure of at least
300 p.s.i. without
leakage.

Hose showing
leaks, burns, worn
places, or other
defects are unfit
for service and
nust be repaired or
replaced.

 Do not attempt to repair a hose with

tape. Tape has a tendency to break
down the hose material, and it is not
a permanent repair.

 Handle the hose carefully when

welding. Avoid dragging it on a
greasy floor. The hose should not be
allowed to come in contact with
flame or hot metal. The hose should
be protected from falling articles,
from vehicles running overit and
from being stepped on. It should not
be kinked sharply.

 At the end of the day or at the end of

the job, roll up the hose and hang it
where it will be out of the way.
Spring-loaded hose reels are
available.

Handpiece
The handpiece
(handle)
connects to
the hoses and
holds the
handpiece
control
valves.

Mixer
The mixer
screws onto
the handle.
It is here
gases are
mixed by a
spiral
action as
they pass
through to
the welding
tip.

Welding Tip
Welding tips direct
the flame to the
weld area. They
come in sizes from
8 to 40 and this
indicates ten times
the sizes of the
hole in the tip. For
example a 12 tip
has 1.2 mm hole.

Welding Torch and Blow

Pipe
Oxygen and the fuel gas having been
reduced in pressure by the gas
regulators are fed through suitable
hoses to a welding torch which mixes
and controls the flow of gases to the
welding nozzle or tip where the gas
mixture is burnt to produce a flame for
carrying out gas welding operation.

There are two types of welding

torches, namely:
(i) High pressure (or equal pressure)
type.
(ii) Low pressure (or injector) type.

 High pressure
blowpipes or
torches are used
with (dissolved)
acetylene stored in
cylinders at a
pressure of 8 bar.

Low pressure
blowpipes are used
with acetylene
obtained from an
acetylene
generator at a
pressure of 200
mm head of water
(approximately
0.02 bar).

Typical torch styles

A small welding torch, with throttle valves

located at the front end of the handle.
Ideally suited to sheet metal welding. Can
be fitted with cutting

attachment in place of the welding head

shown. Welding torches of this general
design are by far the most widely used.
They will handle any oxyacetylene
welding job, can be fitted with multiflame
(Rosebud) heads for heating applications,
and accommodate cutting attachments
that will cut steel 6 in. thick.

A full-size oxygen cutting torch which has

all valves located in its rear body. Another
style of cutting torch, with oxygen valves
located at the front end of its handle.

Care necessary for blowpipes.

Do not remove a
tip with pliers.
Pliers make heavy
gouge marks on
the tip.
Manufacturers
provide a wrench
for their tip design
that should be
used at all times.

Never inspect or
remove a tip while
the tube is hot.
Allow the tip and
the tip tube to cool
at first.

 Keep the orifice at the end of the tip clean at all

times. During welding, weld spatter, scale, and
molten metal may partially close the orifice and
cause the welding flame to be very uneven. The
tip will also erode unevenly from the heat of the
flame. The orifice should be clean often with tip
cleaners. Do not scratch the tip end on the
firebrick or the metal you are welding. Some
welders like to use a wood block for cleaning. The
block removes contamination on the outside of
the tip end, but it does not remove the particles
on the inside of the orifice.

 Do not use the tip

as a hammer. This
is the quickest way
to destroy a tip.

Protect the seat of

the tip. If the tip is
nicked through
dropping or other
rough treatment, it
will leak at the joint
and be dangerous
or impossible to
use.

Accessories
Trolley
A trolley
should be
used to
transport
the welding
equipment
and to
prevent the
cylinders
from falling
over.

Lighting Device
An electronic gas
lighter, a flint gun
or a gas pilot light
should be used to
light the
oxyacetylene
flame. Matches
and butane gas
lighters are
dangerous and
must not be used.

Tip Cleaners
Tip cleaners are
available to keep
the welding tip free
of obstruction. A
straight clean
flame will be easier
to use and
produces better
welds.

Flashback Arrester
This protect against
a full flashback and
the danger that
entails.

 Check valves allow

gas flow in one
direction only
Flashback arrestors
are designed to
eliminate the
possibility of an
explosion at the
cylinder.
Combination Check/
Flashback Valves can
be placed at the torch
or regulator.

Flash Guard Check Valves.

These prevents the reverse flow of
mixed gases in torch hoses or
regulators. The check valve permits
forward flow of gas and closes when
gas begins to flow in a reverse
direction. The forward flow causes a
disc to move overcoming a slight
spring tension. However, a reverse
flow would cause the disk to seat
tightly against a seal, preventing any

 Flash arrestors are generally made of

a sintered metal alloy. The sintered
stainless-steel filter prevents flame
from moving upstream of the
arrestor.

 Neither of these devices protects the

torch or tip. The best way to assure
that accidents dont happen is for the
welder to follow safety operating
procedures.

Table
This sturdy
worktable is
made of steel
and fully
galvanized for
corrosion
protection. It
includes a
holding clamp
for small
workpieces.

Review
For
Class Recitation

Class Recitation time

1

To prevent the occurrence of

flashbacks, a ________ should
be installed between either
the torch and hoses or
regulators and hoses.
A: a two way check
valve.
B: flame screen.
C: flashback arrestor.
D: three way check valve.

2. The hose nuts for oxygen and

acetylene differ greatly, because the
acetylene hose nut has.
A: a left hand thread.
B: has a grove cut around it.
C: may have ACET stamped on it.
D: All of the above.

3. True or False.
An oxygen cylinder has a right-hand
regulator connection thread and is
painted crimson

4. True or False ?
A flint and steel spark lighter is the
generally used to light the oxyacetylene
flame.

5. Acetylene cylinder fuse plugs melt

at a temperature of ________C

6. What is the maximum safe working

gauge pressure for acetylene gas?
A: 8 psig (55 kPa)
B: 15 psig (103 kPa)
C: 22 psig (152 kPa)
D: 30 psig (207 kPa)

7. The color of and oxygen hose on a

oxyacetylene welding outfit is ______?

8. The type of safety device is used on

a oxygen cylinder.
A: A fusible plug
B: A check valve
C: A pressure safety disk
D: A spring loaded plug

9. The color of and acetylene hose on

a oxyacetylene welding outfit is
______?

10. What type of safety device is used

on a acetylene cylinder.
A: A spring loaded plug
B: A pressure safety disk
C: A fusible plug
D: A check valve