Upon completion of this chapter, students

should be able to:-

 Explain Oxy Acetylene Welding(Gas Welding)

◦ Types of Gas Welding

◦ Gas Welding Operation
◦ Gas welding equipment
◦ Identify the basic components of an Oxy Acetylene
welding
◦ Types of flame
◦ Typical startup procedures
CHAPTER 7
 Oxy-fuel welding (commonly called oxy-
acetylene welding, oxy welding, or gas
welding in the U.S.) and oxy-fuel cutting are
processes that use fuel gases and oxygen to
weld and cut metals, respectively.
 fuel gas (i.e. acetylene, hydrogen propane or
butane)
 Definition;
“The oxy-acetylene welding process uses a
combination of oxygen and acetylene gas to
provide a high temperature flame to weld & cut
metals.”

 cutting metal as well as welding, this is because the

welding torch(andang) generates enough heat to bring the
metal up to melting temperature.

 In this process, acetylene is mixed with oxygen in correct

proportions in the welding torch and ignited (dinyalakan).

 The flame resulting at the tip of the torch is sufficiently

(cukup) hot to melt and join the parent metal.
 The oxyacetylene flame reaches a temperature of about
3300°C and thus can melt most of the ferrous and non-
ferrous metals in common use.
 A filler metal rod or welding rod is generally added to the
molten metal pool to build up the seam (jahitan) slightly
for greater strength.
 Oxyacetylene welding does not require electricity and is
typically used for maintenance, in body shops, and the
repair of small parts where other welding process are too
expensive.
 Oxyacetylene welding equipment can also be used for
preheating, cutting metal, case hardening, and annealing.
• A metal joining process, the
method of heating the two metal
parts to be connected, until
melted and merged into one.
 Low- • Receive acetylene gas supply
from gas fired acetylene, a
pressure pressure less than 1.0 bar.
gas welding.

High- • Receive gas from the gas

generator acetylene, with
pressure gas pressure from 1-15 bar.
Welding
• Metal fabrication work involving the sheet metal
thickness greater than 1.0mm up to 3.0mm.

For example,
• In the work of the vehicle body repair work
involves knocking and pasting portions of the
damaged vehicle bodies.
• Piping air-conditioning system , Oil and Gas
piping ,etc .
 The welding profession provides a wide range of
career options.
 Many welding jobs are associated with high-risk
work environments such as underwater
commercial diving or oil pipeline construction.
 Expert welders, such as those working on
pipelines or in underwater environments, are
qualified for the most difficult and, therefore,
highest paying jobs.
Metal Fabrication
 Welders that work in metal fabrication are responsible for the assembly,
shaping and welding of metal pieces incorporated in structures and
machinery.
 From architecture and building construction to automobile and airplane
manufacturing, metal fabrication is a crucial process.
Pipeline Welding
 Pipeline welders -- or pipe "fitters" as they are often called -- are
responsible for producing secure pipelines used for transporting water,
oil, gases and other hazardous materials.
 The degree of difficulty in pipeline welding is higher than most other
welding jobs because many pipeline welding projects take place outdoors
where welders are exposed to unpredictable weather conditions.
Underwater Welding
 Underwater welders are trained to be proficient in "wet welding" and "dry
welding" techniques. Wet welding involves a special electrode with DC
power and dry welding takes place in a hyperbaric chamber filled with a
breathable mixture of helium and oxygen.
 Fuel gas cylinder with pressure regulator
 Oxygen cylinder with pressure regulator
 Welding torch
 Blue/green oxygen hose
 Red fuel gas hose
 Trolley for transportation of the gas cylinders
 Check Valve
 Non-return Valve
 Welding Torch
 All threaded
fittings oxygen
right direction

All threaded
fittings
acetylene right
direction
 Oxygen and acetylene pressure regulators
perform two functions:

◦ Control the flow of gas from the cylinder to

maintain the required working pressure.
◦ Produce a steady flow of gas under varying cylinder
pressures.
 Equipped with two gauges:

◦ A cylinder pressure gauge,

which indicates the actual
pressure in cylinder

◦ Working pressure, which

shown the working, or line,
pressure used at the torch.
Single Stage Regulators Two Stage Regulators
• has a high pressure
area where the high
pressure of the
cylinder directly into
this space.

• pressure readings can

be seen on the needle
ready regulators and
reduced the pressure
to work in accordance
with appropriate
adjustments using the
adjustment screw
regulators pad.

• Regulators security
level is lower than the
two-stage Regulators
• has two chambers of pressure
and low pressure area.

• High pressure area at

regulators accept the high
pressure in the cylinder and
the pressure readings can be
read on the pressure gauge.

• While the low-pressure area

to receive the controlled
admission of gas from high
pressure column by adjusting
the adjustment screw on the
regulators according to the
required working pressure.

• The level of security is better

than regulators one stage.
 Most regulators have two stages: the first stage of the
regulator is a fixed-pressure regulator whose
function is to release the gas from the cylinder at a
constant intermediate pressure, despite the pressure
in the cylinder falling as the gas in the cylinder is
used.

 The adjustable second stage of the regulator controls

the pressure reduction from the intermediate
pressure to the low outlet pressure.

 The regulator has two pressure gauges, one

indicating cylinder pressure, the other indicating hose
pressure. The adjustment knob of the regulator is
sometimes roughly calibrated for pressure, but an
accurate setting requires observation of the gauge.
 Common gauge settings for cutting
◦ 1/4” material Oxy 30-35psi Acet 3-9 psi
◦ 1/2” material Oxy 55-85psi Acet 6-12 psi
◦ 1” material Oxy 110-160psi Acet 7-15 psi

 Check the torch manufactures data for optimum

pressure settings
 The hose pipes are used for the
supply of gases from the
pressure regulators.

 Hoses are are fabricated from

rubber

 Oxygen hoses are green in color

and have right hand thread.

 Acetylene hoses are red in color

with left hand thread.

 Left hand threads can be

identified by a grove in the body
of the nut and it may have “ACET”
stamped on it
 A connection consists of
a nipple that is forced
into the hose and a nut
that connects the nipple
to the regulator and the
torch.

 The acetylene nut can be

distinguished from the
oxygen nut by the notch
that runs around the
center, indicating a left-
hand thread.
 It is a tool for mixing oxygen and acetylene in
correct proportion and burning the mixture at the
end of a tip.

 Gas flow to the torch is controlled with the help of

two needle valves in the handle of the torch.
 The torch is the part that the welder holds and
manipulates to make the weld.

 It has a connection and valve for the fuel gas and a

connection and valve for the oxygen, a handle for
the welder to grasp, a mixing chamber (set at an
angle) where the fuel gas and oxygen mix, with a
tip where the flame forms.
 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.
 The tip sizes are identified by the diameter of the
opening.

 The diameter of the tip opening used for welding

depends upon the type of metal to be welded.

 Welding on different thicknesses of metal is

possible because torches are equipped with
different size heads or tips.
 Manifold system
◦ Allows the necessary
volume to be supplied
to work area.

 Flash
arrestor(perangkap)
◦ Safety device that
prevents an explosion or
a backfire in the torch or
torch head from
reaching the regulator
and acetylene cylinders.
 Flame is the most important means to control the
welding joint and the welding process.

 The correct type of flame is essential (penting) for

the production of satisfactory welds.

 The flame must be of the proper size, shape and

condition in order to operate with maximum
efficiency.
 There are three basic types of oxy-acetylene
flames:

1.Neutral welding flame (Acetylene and oxygen in

equal proportions).

2. Carburizing welding flame or reducing (excess

of acetylene).

3. Oxidizing welding flame (excess of oxygen).

 Verify that equipment visually appears safe IE: Hose
condition, visibility of gauges

 Clean torch orifices with a “tip cleaners” (a small wire

gauge file set used to clean slag and dirt form the
torch tip)

 Crack (or open) cylinder valves slightly allowing

pressure to enter the regulators slowly

 Opening the cylinder valve quickly will “Slam” the

regulator and will cause failure.
 Never stand directly in the path of a regulator when
opening the cylinder
 Check for leaks using by listening for “Hissing” or by
using a soapy “Bubble” solution
 Adjust the regulators to the correct operating
pressure
 Slightly open and close the Oxygen and Acetylene
valves at the torch head to purge any atmosphere
from the system.
 Always use a flint and steel spark lighter to light the
oxygen acetylene flame.
 Never use a butane lighter to light the flame