Adjusting Screw Screwed Out

Adjusting Screw
Bonnet

Spring Button
Diaphragm Plate Nut
Compression Spring
Diaphragm Plate
Dia-Blok Construction
Diaphragm
Bonnet Screws
Diaphragm Gasket
Check Valve Spring
Low Pressure Outlet
Yoke
Safe-T-Check Valve
High Pressure Inlet
Nozzle (Seat)
Body Quick Replaceable
Yoke Clamping Screw Operating Seat Cylinder Coupling
Seat Block-Four Seats
Yoke Guide Rear Spring

Back Cap

Fig. 5-21 Internal construction of single-stage cylinder regulator.

Adapted from Thermadyne Holdings Corporation

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 C S
connections are tight. V
Use regulators only for the gas and pressures for
which they are intended. 2,200 lbs
Have regulators repaired only by skilled mechanics
who have been properly trained and qualified. O Flexible
10 lbs Diaphragm

For video on regulator burnout, please visit

www.mhhe.com/welding. C S

V
Regulator Construction To better understand the work-
ings of the internal mechanism of a gas regulator, 2,200 lbs
study Fig. 5-22. Let us consider an oxygen regulator
as an example. The oxygenunder high pressure and O Flexible
coming directly from the oxygen cylinderenters the 10 to 2,200 lbs Diaphragm

regulator at the left at 2,200 p.s.i., and it must leave the

regulator at the desired pressure for welding, perhaps
10 p.s.i.
Before the oxygen is allowed to enter at the left, ten-
sion on the spring (S) puts pressure on the flexible dia-
phragm, deflecting it to the left, which in turn causes it
to contact the valve stem, opening the valve (V). If the
oxygen tank is opened and the gas is permitted to flow
Fig. 5-22 Connecting the outlet shown in the top sketch to the
inlet of the lower demonstrates the principle of two-stage regulators.
into the chamber (C), the full force of 2,200 p.s.i. pressure
is exerted against the diaphragm, causing it to move to the
right. Thus, the pressure against the valve stem is removed
so that the valve (V) closes.

Gas Welding Chapter 5151

 When, because of the requirements of the welding Adjusting
or cutting flame, oxygen has been withdrawn from the Screw
chamber (C), the pressure falls below a certain point. Bonnet
Spring

Therefore, the tension spring (S) becomes the greater

force and deflects the diaphragm to the left, reopening Diaphragm
the valve to permit more high pressure oxygen to enter Body Stem
the chamber. Bear in mind that the force that opens the Seat
Outlet
valve is provided by the tension of the spring, while the Inlet

force that closes the valve is provided by the high gas Spring
A
pressure from the tank. When these two forces are bal-
anced, a constant flow of oxygen to the torch results.
Adjusting
When the tension of the spring is properly adjusted by Screw
means of the regulator-adjusting screw (Figs. 5-20 and Spring
5-21, pages 150151), the constant pressure desired is Bonnet
maintained in the chamber (C). Thus, a constant pres- Diaphragm
sure can be withdrawn from the chamber, providing an Body Yoke
even flow of oxygen to the torch.
Regulators are designated as single-stage and two- Outlet Inlet
stage regulators. The operation of the single-stage regula- Nozzle Seat
tor has just been explained. In the two-stage regulator the
pressure reduction is accomplished in two stages. In the Spring B
first stage the spring tension has been set so that the pres-
sure in the high pressure chamber is a fixed amount. For
Adjusting
example, it may be set at 150 p.s.i. The gas then passes Screw
into a second reducing chamber that has a screw adjust- Spring
Bonnet
ment similar to that in the single-stage regulator. This
adjustment makes it possible to obtain any desired pres-
Diaphragm
sure. The principle of the two-stage regulator is shown in
Fig. 5-22, page 151, in which the upper sketch represents Body
Stem

the first stage; and the lower, the second. Figure 5-23 il- Spring

lustrates three typical regulator designs. Outlet Inlet

For the most part, single-stage regulators are used with
manifold systems. In these systems the 2,200 p.s.i. pres-
sure is reduced at the manifold before it enters the piping
system through a heavy duty regulator on the manifold.
The relatively low manifold pressure is further lowered
at the work station to the required pressure by the single-
stage regulator.
Regulator springs are made of a good grade of spring
steel. The diaphragm may be made of brass, sheet spring
steel, stainless steel, or rubber.
When a number of stations are serviced by a line gas
system, individual oxygen and acetylene regulators are
required at each station. These regulators are smaller
than cylinder regulators because they are not subject
to high cylinder pressure. Figure 5-24 shows the dif-
ference in the internal construction of a tank and a line
regulator.
Although the mechanical details of regulator construc-
tion vary among different manufacturers, the fundamen-
tal operating principles are the same for all oxyacetylene
regulators used for welding and cutting.
Seat
Stem
Spring
Diaphragm
C
Fig. 5-23 Typical gas regulators: (A) single-stage stem
type, (B) single-stage nozzle type, and (C) two-stage.
Adapted from Thermadyne Holdings Corporation
Welding Torches
The welding torch is an apparatus for mixing oxygen and
acetylene in the proportions necessary to carry on the weld-
ing operation. It also provides a handle so that the welder
can hold and direct the flame while welding. The handle
has two inlet gas connections: one for oxygen and the
other for acetylene. Each inlet has a valve that controls
the volume of oxygen or acetylene passing through. By
means of these valves, the desired proportions of oxygen
and acetylene are allowed to flow through the torch where

152Chapter 5Gas Welding

 Type O Single-Stage Cylinder Type O Single-Stage
(or Master) Regulator Station Regulator

3 5
4
3
5

High-Pressure Gas Entering Low-Pressure Gas Leaving

Fig. 5-24 Internal construction of tank and line regulator. There are two major types of regulators. First, the single-stage cylinder type is the
most used and is shown in the top drawing. (When gases are manifolded, a manifold version of this type is used, called a master.) The second kind
of regulator, shown underneath the first type, is the single-stage station regulator. It is used to reduce the outlet pressure of the master regulator to
the pressures commonly used for welding and cutting at the individual stations.
1 .Quick replacement cylinder couplingused on cylinder type regulators only, for added strength.
2.Dia-Blok constructiondiaphragm and seat are positively connected by means of a yoke, so that both the seat and diaphragm move at
the same timeproviding long seat life and minimum pressure fluctuation.
3.Diaphragmstainless-steel diaphragms are used in single-stage cylinder regulators and master regulators, whereas reinforced rubber
diaphragms are used in the lower pressure station regulators.
4.Safe-T-Chek valvelocated in the nozzle of both single-stage cylinder and master regulators. This valve will automatically close if the seat
of the regulator is off the nozzle when full cylinder pressure enters. It protects against seat failure.
5.Regulator seata multiseat block is used on cylinder type single-stage regulators, which can be rotated for seat change. A single seat is
used on the lower pressure single-stage station regulator.
Adapted from Thermadyne Holdings Corporation

they are thoroughly mixed before issuing from the torch
tip. Each torch can be supplied with a wide range of weld-
ing tip sizes so that a large number of flame types and
sizes can be set up for the various thicknesses of metal to
be welded.
Two types of oxyacetylene welding torches are in
common use: the injector and the equal (balanced-
pressure) types. Figure 5-25, page 154 shows an inter-
nal view of the injector torch. The acetylene is carried
through the torch and tip at low pressure by the suction
force of the higher oxygen pressure passing through the
small orifice of the injector nozzle, Fig. 5-26, page 154.
The mixing head and injector are usually made as an
integral part of the tip, and they are designed to cor-
respond to the various tip sizes. The oxygen pressure
used with this type of torch is considerably higher than
that used with the equal-pressure torch.
In the equal-pressure (balanced-pressure) torch,
Fig. 5-27, page 155, both gases are delivered through the
torch to the tip at essentially equal pressures. The mixer

Gas Welding Chapter 5153

 Mixing Chamber
Injector Nozzle
Oxygen
Acetylene
Mixed Gases
Fig. 5-25 This injector torch is designed for both low and medium pressure operations. The injector is shown in Fig. 5-26.
Acetylene
Oxygen
Mixed Gases
Fig. 5-26 As the oxygen issues at relatively high velocity from
the tip of the injector, it draws the proper amount of acetylene into
the stream. The oxygen and acetylene are thoroughly mixed before
issuing from the torch tip.
or mixing head is usually a separate replaceable unit in
the body of the torch into which a variety of tips may be
fitted. See Fig. 5-28, page 156 for a comparison of the
equal-pressure and injector types of mixing chambers. A
standard mixer can provide for the variety of tip sizes.
Light gauge sheet metal welding and aircraft welding
are usually done with a torch equipped with a smaller
handle than the standard torch. This type of welding re-
quires a delicate touch, and the heavier standard torch
would be clumsy. An internal view of the balanced-
pressure torch and the cutting attachment for light
welding is shown in Fig. 5-29, page 157. Note the high
pressure oxygen valve (poppet).
For lightweight portable type work, see Fig. 5-30,
page 157. One great advantage of the OAW process is
that it requires no outside source of power. It is a self-
contained system.
Torch Tips Oxyacetylene welding requires a variety of
flame sizes. For this reason a series of interchangeable
heads or tips of different sizes and types are available. The
size of the tip is governed by the diameter of the opening
at the end of it. The tip size is marked on the side of the
tip. The most common system consists of numbers that
154Chapter 5Gas Welding
Oxygen
Acetylene
SH OP TA L K
Transistorized Advantages
Transistorized welding machines have
several advantages as advanced welding power sources.
1. Stable arc.
2. Current, and its shape in pulse mode, can be pre-
cisely adjusted.
3. Stable against disturbances like voltage fluctuation.
4. Arc current and voltage feedback can be controlled
from outside (and automated) sensors.
may range from 000 to 15. In this system the larger the
number, the larger the hole in the tip and the greater the
volume of heat that is provided. An increased volume of
gas is also required for the flame. Table 5-2 (p. 156) gives
information concerning one manufacturers balanced-
pressure torch and tip sizes.
You will recall that tips for injector torches are pro-
vided with individual mixers so that the mixer and tip are
one unit. Tips for medium- or equal-pressure torches do
not have the mixer as part of the tip. Mixers are part of the
torch and serve a number of tip sizes. Also available are
universal mixers designed to give proper gas mixtures for
a full range of tip sizes.
Most welding tips are made of pure drawn copper
because of the ability of this material to dissipate heat
rapidly. Since copper is soft and tips are subject to consid-
erable wear, both at the tip and threaded ends, tips must
be handled carefully. The following precautions should be
observed:
D
 o not remove a tip with pliers. Pliers make heavy
gouge marks on the tip. Manufacturers provide a
 Snap Ring
O-Ring Needle Valve Assembly
Mixer Stem Union Nut Handle Head Handle
WG Series Tips Mixer Shell

Mixer Body O-Ring

Anti-friction Washer Mixer Head Needle Valve Assembly

Welding Torch

Poppet Valve Lever Bolt

Cutting Head Tube Packing Poppet Valve Gland

Cutting Head Tube Poppet Valve Stem Packing

H. P. Gland Nut

Poppet Valve Stem Poppet Valve Lever

Cutting Head
Union Shank

O-Ring

Cutting Head Nut M.P. Mixer Anti-Friction Washer

Mixer Shell
Valve Body Poppet Valve Seat
Mixer Nut
Poppet Valve Gasket
Needle Valve
Assembly Poppet Valve Seat Holder
L Series Tips Poppet Valve Guide Cap

Cutting Attachment

Fuel Gas Oxygen Mixed Gases

Fig. 5-27 Internal view of balanced-pressure welding torch and cutting attachment. Adapted from Thermadyne Holdings Corporation
155
 Torch Head
2 Mixer Nut
Oxygen Mixer Tip

Cross-Sectional View of Mixing Chamber

Fuel
1 3
Gas 2 The two gases are fed in at points (1) fuel gas and (2)
oxygen, there being a multiplicity of holes for the latter.
The gases are mixed, beginning at point (3), throughout
the mixing chamber, as shown by the various arrows.

Torch Head

2 Mixer Nut
Fuel Gas
Mixer Tip

Oxygen 1 3
2 The oxygen passing through the Venturi (1), aspirates
the fuel gas available in chamber (2). The gases are
mixed, beginning at point (3), throughout the mixing
chamber, as shown by the various arrows.
B

Fig. 5-28 Basic elements of welding torch mixers: (A) positive (balanced-
pressure) type, (B) injector type.

Table 5-2 Gas Pressures for Different-Sized Welding Tips

Thickness Acetylene Oxygen Oxygen Lineal Ft

of Metal Pressure Pressure Consumption Welded
Tip No. (in.) (lb) (lb) per Hour per Hour
1 32
1 1
2 1
2 7.80 30
2 16
1
1 1 7.90 25
3 3
32 1 1 2 1
8.10 20
4 8
1
1 2 9.75 15
5 3
16 112 212 16.80 9
6 5
16 2 2 2
1
26.40 6
7 8
3
3 5 39.35 5
8 2
1
5 8 51.15 4
9 8
5
8 14 69.10 3
10 3
4 & up 10 18 80.00 2

Note: Oxygen consumption per hour was measured with the Hydrex Flow Indicator, with maximum size flame. Information is
intended for estimating purposes only and should amply cover adverse conditions.
Source: Modern Engineering Co.

156Chapter 5Gas Welding

 Oxy. Hose Coupling Bushing
Valve Stem
Friction Washer
Valve Stem Handle
A-V Tip Gland Washer
Spring Gland Nut

Med. Press. Mixer Fig. 5-31 Tip cleaners used to clean out the
Handle
Mixer Nut Snap Ring Handle Head orifices of welding and cutting tips. David A. Tietz/
Editorial Image, LLC
Armored Attachment Gasket
Union Nut
Acet. Hose Coupling Bushing
wrench for their tip design that should be
Poppet Valve Guide Cap used at all times.
Poppet Valve Spring
Poppet Valve Seat
N
 ever insert or remove a tip while the tip
Poppet Valve Guide Cap Gasket tube is hot. Allow the tip and the tip tube to
Poppet Valve Lever Poppet Valve Stem Packing cool first.
Spring
Poppet Valve Lever Keep the orifice at the end of the tip clean
Poppet Valve Lever at all times. During welding, weld spat-
Bolt and Nut Poppet Valve Gland
Poppet Valve Lever Adjustment
ter, scale, and molten metal may partially
Poppet Valve Lever Adj. Screw
Screw Locknut close the orifice and cause the welding
Cutting Attachment
flame to be very uneven. The tip will
H. P. Tube Gland Nut Tube Packing also erode unevenly from the heat of
H. P. Oxygen Tube Valve Body the flame. The orifice should be cleaned
Cutting Head Union often with tip cleaners, Fig. 5-31. Do not
Attachment
Nut scratch the tip end on the firebrick or the
Cutting Head metal you are welding. Some welders
Nut Union
Shank like to use a wood block for cleaning.
A-J Tip Mixer Gas Tube The block removes contamination on
Medium Armored
Mixer Gas Tube Nut Press Attachment
the outside of the tip end, but it does not
Mixer Gasket remove the particles on the inside of the
orifice.
Fig. 5-29 Internal view of the balanced-pressure torch used for light welding.
A detachable cutting head is also shown.
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.

Oxygen and Acetylene Hose

Fig. 5-30 Portable oxyfuel setup. Thermadyne Industries, Inc./
Victor Equipment Company
The hose used for welding and cutting, Fig. 5-32, page 158,
is especially manufactured for the purpose. It must be
strong enough to resist internal wear, flexible enough so
that it does not interfere with the welders movement,
and able to withstand a great deal of abrasive wear on
the job. The proper designation hose must be used such
as RMACGA Grade T hose for fuel gas (including acet-
ylene) to prevent hose failure. Grade R and RM are for
acetylene only.
Hose is usually made of three layers of construc-
tion. The inner lining is composed of a high grade of
gum rubber. This is surrounded by layers of rubber-
impregnated fabric. The outside cover is made of a
colored vulcanized rubber that is plain or ribbed to

Gas Welding Chapter 5157