Chapt 5 Gas Weld

PowerPoint to accompany
Welding
Principles and Practices
4th edition
Edward R. Bohnart
Gas
Welding
Chapter 5
© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

2
Objectives
1. Describe the history of oxyacetylene
welding (OAW).
WELDING: Principles and Practices, 4e
2. List and describe the properties and

distribution systems for the gases used
for OAW.
3. Explain the safety issues of OAW.
4. List the equipment used for the OAW
process.

3
Oxyacetylene Welding
• Definition:
– Join metal by heating surfaces to be joined to
melting point with gas flame

– Fusing metal into homogeneous mass
– Letting it solidify into a single unit
• Flame in cone reaches temperatures as
high as 5800º to 6300ºF
• Filler rod may or may not be used to
intermix with molten pool

4
Oxyacetylene Process
• During first part of the 20th century it was
used as a major welding process both for
fabrication and construction, maintenance

and repair
• Today its use is limited for industrial
production purposes
• Still used for brazing, soldering, metalizing;
welding metals with low melting points;
general maintenance and repair work
History of Oxyacetylene 5
Welding
• Early Egyptians, Greeks, and Romans
used alcohol or oil flame to fuse metals
• In nineteenth century various gases tested

– Used in laboratory in working with precious
metals
– In 1847, Robert Hare fused platinum with
oxyhydrogen flame
– In 1880, production of oxygen and hydrogen
through electrolysis of water made distribution
of gases in cylinders under pressure
– Late 1800s experiments done with oxygen-
coal gas and air-hydrogen flames
Discoveries Leading to the 6
• In 1836, Edmund Davey discovered
acetylene gas
• In 1862, acetylene gas produced from

calcium carbide
• In 1895, Thomas L. Willson produced
calcium carbide commercially
– Used for residential lighting
• In 1895, LeChatelier discovered that
combustion of acetylene with oxygen
produced flame hotter than any other gas
flame
Discoveries Leading to the 7
• In 1900, Edmond Fouche invented high
pressure acetylene torch
– Later designed low pressure torch (worked on

injector principle)
• In 1906, Eugene Bourbonville brought first
welding torch to this country
– Process first used for maintenance and repair
• During World War I oxyacetylene welding
became production tool

8
Gases
• Oxyacetylene welding process uses two
principal gases
– Oxygen and acetylene

• Other gases can be used for cutting and
heating
– Propane
– Natural gas
– Mapp® gas
• Stored in different size cylinders
Various Fuel Gas 9
Efficiencies
Normal
Btus Usable heat Flame Oxygen velocity
Fuel Gas (ft3) (s/ft2) temp. per ft3 of fuel (ft/s)
Acetylene 1433 12,700 5,420ºF 1.04 17.7

Mapp®2 2381 5,540 5,301ºF 2.40 7.9
Propane 2309 5,500 5,190ºF 4.00 11.9
Natural gas3 918 5,600 5,000ºF 1.50 15.2
(Mpls./St.Paul)
Hydrogen 275 7,500 4,600ºF 0.25 36

10
Various Gas Cylinders
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Thermadyne Industries, Inc.

11
Oxygen
• Gaseous chemical element in air
– Necessary for life
• Most abundant chemical element in crust

of Earth
• No color, odor, or taste
• Does not burn, but supports combustion
– Substances that do not burn in air will in
oxygen

12
Oxygen Production
• Two commercial processes used in
production of oxygen
– Separation of water into oxygen and hydrogen

by electrolysis of water
– Separation of air into oxygen and nitrogen by
liquefying air
• Commercial oxygen production

13
Oxygen Distribution
• Aluminum cylinders
– Used for medical gases (smaller size)
– Made of high strength 6061-T6 alloy

• Steel cylinders
– Made from single plate of high-grade
steel
– Heat treated to develop maximum
strength and hardness
– Seamless, drawn-steel vessels with iron
neck ring shrunk on at top and cylinder
value screwed into neck
– High pressure – undergo rigid testing

14
Valve Mechanisms
• Must be opened to release
oxygen
• Double-seated valve perfectly

tight when completely open
or closed
• Another type of valve requires
only a turn or two to open
– Valve protected from damage
by iron cap that screws on neck
ring
15
Gas Cylinders
• Charged with oxygen at pressure of about
2,200 p.s.i. at 70ºF
• Gas temperature
– Increase: gas expands and increases pressure
– Decrease: gas contracts and reduces pressure
• Safety device on cylinder valve to blow off
oxygen when excess pressure
– Occurs, oxygen lost
– DO NOT store where cylinder can be
overheated

16
Capacity of Cylinder
• Three cylinder sizes used for welding and
cutting
• Gas suppliers fill tanks with varying

amounts
– Large size: 220–244 cubic feet of oxygen
• Full: 148 to 152 pounds; Empty: 130–133 pounds
– Middle size: 110–122 cubic feet of oxygen
• Full: 89 to 101 pounds; Empty: 79–93 pounds
– Small size: 55–80 cubic feet of gas
• Full: 67 pounds; Empty: 60 pounds

17
Safety Precautions
• Take special care to keep oil and grease
away from oxygen
• When using, do not place cylinders where

oil might drop on them from overhead
bearings
• Never use oxygen in pneumatic tools or to
start internal combustion engines
• Never use oxygen to blow out pipe or hose
lines, dust clothes or create head pressure
in tank of any kind

18
Safety Precautions
• Do not store oxygen cylinders near
acetylene generator, carbide, acetylene, or
other fuel-gas cylinders

• Do not use cylinder as roller or lift it by cap
• Keep cylinders away from welding
operation and close cylinder valve when
work completed
• Keep cylinders away from any electrical
contact

19
Acetylene
• Most widely used of all fuel gases
– Both welding and cutting
• Generated as result of chemical reaction

that takes place when calcium carbide
comes in contact with water
• Tests show oxyacetylene flame
temperatures up to approximately 6,300ºF
– Very rapid rate of preheating
– Burns with smoky flame, gives off carbon, has
peculiar odor
Characteristics of an Effective 20
Welding Fuel Gas

• High flame temperature
• High rate of flame propagation
• Adequate heat content

• Minimum chemical reaction of flame with
base and filler metal
Acetylene most closely matches all these

requirements and is used for welding purposes.

Acetylene Production and 21
Distribution
• Commercial acetylene made from calcium
carbide – referred to as carbide
– Gray, stonelike substance

– Product of smelting coke and lime in electric
furnace
– Several sizes available
• Distributed in standard steel drums
– 100 pounds for use in acetylene generators

22
Acetylene Cylinders
• Constructed differently from oxygen cylinders
– Free acetylene should not be stored at pressure
above 15 p.s.i.
• Safety solved by packing cylinders with
porous material saturated with acetone
– Acetone: liquid chemical having property of
dissolving or absorbing many times the volume
of acetylene
• Strong steel container (packed completely
full)
• Handle with care
23
Three Basic Acetylene
Cylinders
24
Valve Mechanisms
• Acetylene drawn off through valve
– Some cylinders valve located in recessed top
– Others valve located on convex top

• Simpler in construction than oxygen valve
– Does not have to stand high pressure
• Opened only about 1-1/2 turns
– Can be turned off quickly in case of fire
• Safety fuse plugs also provided

25
Capacity of Cylinder
• Full cylinder of acetylene has pressure of
about 225 p.s.i.
• Two sizes used for welding and cutting

– Large size contains 300 cubic feet of
acetylene and weighs about 232 pounds
when full
– Small size contains 100 cubic feet and weighs
91 pounds when full
• Two special sizes (10 cubic ft. and 40
cubic ft.)
• Not all acetylene in cylinder can be used
26
Safety Precautions
Remember acetylene will burn.
It will form explosive mixture with air.
• Do not leave acetylene cylinders on their

sides
– Store valve end up
• Store cylinders in well-protected,
ventilated, dry location
– Away from highly combustible material or
sources of heat
– Keep valve cap on when not in use
27
Safety Precautions
• Use warm (not boiling) water on the valve if
it becomes clogged with ice (Never a flame!)
– Fusible safety plugs melt at boiling point of

water
• Handle acetylene cylinders carefully
– Damages could cause leakage
• Advise supplier immediately if acetylene
leaks around valve spindle when valve
opened
– Close spindle and move cylinder to outside area
• Never tamper with fuse plugs
28
Propane Gas
• Hydrocarbon present in petroleum and
natural gas
• Used primarily for oxyfuel heating, cutting,
soldering and brazing

• Sold and transported in steel cylinders
containing from 20 to 100 pounds of liquefied
gas
– Also supplied by tank car and bulk delivery
• Oxypropane flame temp less than
oxyacetylene
– Takes longer to bring steel to melting point
– Used for soldering and alloy brazing

29
®
Mapp Gas
• Liquefied acetylene compound
– Fuel gas for oxyfuel heating and cutting
• Strong smell (aid in discovering leaks)

• Mixed with oxygen, flame is 5,301ºF
• Heating and cutting somewhat slower
– Lower temperature
• Overall expenses lower due to reduced
handling costs and lower gas costs

30
®
Mapp Gas
• Use as fuel gas for heating and cutting is
growing
• Distributed in bulk or steel cylinders

– Shutoff valve similar to ones on acetylene
cylinder
• Liquefied and stabilized so can be used at
pressures as high as 375 p.s.i. at 170ºF
• Explosive limits lower than acetylene
• Can be stored in free state and at high
pressures
Safety in Handling Mapp® 31
Gas
• Forms an explosive mixture with air
• Same general precautions used with
handling acetylene cylinders should be

observed
• Safest of industrial fuels
– Explosive limits of Mapp® gas vapor in air and
oxygen much narrower than acetylene, same
as propane and natural gas
– Can smell it at concentrations as low as 0.01%

General Cylinder Handling, 32
Storage, and Operation Safety
Regulations
1. All portable cylinders used for the storage and

shipment of compressed gases shall be constructed
and maintained in accordance with the regulations of
the U.S. Department of Transportation, 49 CFR Parts
171–179.
2. Compressed gas cylinders shall be equipped with
connections complying with the American National
Standard Compressed Gas Cylinder Valve Outlet and
Inlet Connections, ANSI B57.1-1965.

Regulations
3. Compressed gas cylinders shall be legibly marked, for

the purpose of identifying the gas content, with either
the chemical or the trade name of the gas. Such
marking shall be by means of stenciling, stamping, or
labeling and shall not be readily removable. Whenever
practical, the marking shall be located on the shoulder
of the cylinder. This method conforms to the American
National Standard Method for Marking Portable
Compressed Gas Containers to Identify the Material
Contained, ANSI Z48.1-1954.

Regulations
4. All cylinders with a water weight capacity of over 30

pounds (13.6 kilograms) shall be equipped with means
of connecting a valve protection cap or with a collar or
recess to protect the valve.
5. Cylinders shall be kept away from radiators and other
sources of heat.

Regulations
6. Inside of buildings, cylinders shall be stored in a well-

protected, well-ventilated, dry location, at least 20 feet
from highly combustible materials such as oil or
excelsior. Cylinders should be stored in clearly
identified assigned places away from elevators, stairs,
or gangways. Assigned storage spaces shall be located
where cylinders will not be knocked over or damaged
by passing or falling objects, or subject to tampering by
unauthorized persons. Cylinders shall not be kept in
unventilated enclosures such as lockers and
cupboards.
7. The valves on empty cylinders shall be closed.

Regulations
8. For cylinders designed to accept a valve protection

cap, the cap shall always be in place, hand-tight,
except when cylinders are in use or connected for use.
9. For fuel-gas cylinder storage inside a building,
cylinders, except those in actual use or attached ready
for use, shall be limited to a total gas capacity of 2,000
cubic feet or 300 pounds of liquefied petroleum gas.
10. Oxygen cylinders shall not be stored near highly
combustible material, especially oil and grease, or near
acetylene or other fuel-gas cylinders, or near any other
substance likely to cause or accelerate fire.

Regulations
11. Oxygen cylinders in storage shall be separated from

fuel-gas cylinders or combustible materials (especially
oil or grease), a minimum distance of 20 feet or by a
noncombustible barrier at least 5 feet high having a
fire-resistance rating of at least one-half hour.
12. Cylinders, cylinder valves, couplings, regulators, hoses,
and apparatus shall be kept free from oily or greasy
substances. Oxygen cylinders or apparatus shall not be
handled with oily hands or gloves. A jet of oxygen must
never be permitted to strike an oily surface, greasy
clothes, or enter a fuel oil or other storage tank.

Regulations
13. A cradle, boat, or suitable platform shall be used when

transporting cylinders by a crane or derrick. Slings or
electric magnets shall not be used for this purpose.
Valve-protection caps shall always be in place on
cylinders designed to accept a cap.
14. Cylinders shall not be dropped, roughly handled, or
struck or permitted to strike each other violently. Rough
handling, knocks, or falls are liable to damage the
cylinder, the valve, or the safety devices and cause
leakage.

Regulations
15. Cylinder valves shall be closed before cylinders are

moved.
16. Cylinder valves shall be closed when work is finished.
17. Valve-protection caps shall not be used for lifting
cylinders from one vertical position to another. Bars
shall not be used under valves or valve-protection caps
to pry cylinders loose when frozen to the ground or
otherwise fixed; the use of warm (not boiling) water is
recommended. Valve-protection caps are designed to
protect cylinder valves from damage.

Regulations
18. Unless cylinders are secured on a special truck,

regulators shall be removed and valve-protection caps,
when provided for, shall be put in place before
cylinders are moved.
19. Cylinders shall never be used as rollers or supports,
whether full or empty.
20. Cylinders not having fixed hand wheels shall have
keys, handles, or nonadjustable wrenches on valve
stems while these cylinders are in service. In multiple-
cylinder installations only one key or handle is required
for each manifold.

Regulations
21. Cylinders shall be kept far enough away from the actual
welding or cutting operation so that sparks, hot dross,
or flame will not reach them, or fire-resistant shields
shall be provided.
22. The numbers and markings stamped into cylinders
shall not be tampered with.
23. No one shall tamper with safety devices on cylinders
or valves.

Regulations
24. Cylinders shall not be placed where they might become
part of an electric circuit. Contacts with third rails,

trolley wires, or the like shall be avoided. Cylinders
shall be kept away from radiators, piping systems, and
layout tables that may be used for grounding electric
circuits, such as for arc welding machines. Any practice
such as the tapping of an electrode against a cylinder
to strike an arc shall be prohibited.
25. No person, other than the gas supplier, shall attempt to
mix gases in a cylinder. No one, except the owner of
the cylinder or person authorized by the owner, shall
refill a cylinder.

Regulations
26. A hammer or wrench shall not be used to open cylinder

valves. If valves cannot be opened by hand, the
supplier shall be notified.
27. Cylinder valves shall not be tampered with nor should
any attempt be made to repair them. If trouble is
experienced, the supplier should be sent a report
promptly, indicating the character of the trouble and the
cylinder’s serial number. Supplier’s instructions as to
its disposition shall be followed.

Regulations
28. Fuel-gas cylinders shall be placed with valve end up

whenever they are in use. Liquefied gases shall be
stored and shipped with the valve end up.
29. Safety devices shall not be tampered with.

Regulations
30. Before connecting a regulator to a cylinder valve, the

valve shall be opened slightly and closed immediately.
The valve shall be opened while standing to one side of
the outlet; never in front of it. Never crack a fuel-gas
cylinder valve near other welding work or near sparks,
flame, or other possible sources of ignition.
31. Before a regulator is removed from a cylinder valve, the
cylinder valve shall be closed and the gas released
from the regulator.

Regulations
32. Nothing that may damage the safety device or interfere

with the quick closing of the valve shall be placed on
top of an acetylene cylinder when it is in use.
33. If cylinder valves or fittings are found to have leaks that
cannot be stopped by closing the valve or fitting, the
cylinders shall be plainly tagged and taken outdoors
away from sources of ignition. A sign should be placed
near the leaky cylinders warning unauthorized
personnel not to approach them. The supplier should
be promptly notified, and the supplier’s instructions for
the return of the cylinders followed.

47
Manifold Distribution
• Supplies both oxygen and fuel gas to
number of work stations
• Acetylene manifolds must be equipped

with flash arrester to prevent flashback
through manifold into cylinders
• Each cylinder connected to manifold by
means of an individual pigtail flash arrester
and backcheck valves

48
A typical station
outlet for both
oxygen and
acetylene
pipelines from
the source.

49
Manifold Regulator
• Reduces pressure to 50 or 75 pounds in
line that goes to station outlets in shop
– Full pressure of 2,000 p.s.i.

in oxygen manifold pipes
• Work station also equipped
with acetylene and oxygen
regulator for further
pressure control

50
Oxygen Manifold
Installation
51
Manifold Systems
• Piping
– Acetylene: should be steel or wrought iron
– Oxygen: can use copper

• Range from very simplistic
to highly sophisticated
automatic systems
– For virtually any gas control
requirement
Thermadyne Industries, Inc./Victor Equipment Company

52
Acetylene Cylinder
Manifold System
53
Acetylene Generators
• Two general types
– Calcium carbide dropped into water
– Water allowed to drip on carbide

• Carbide-to-water generators used to
produce acetylene gas for welding and
cutting
– Water absorbs heat given off by chemical
reaction
– Gas purified by bubbling through water

54
Rexarc
Acetylene Generator
55
Acetylene Generators
• Two classes of generators
– Low pressure (less than 1 p.s.i.)
– Medium pressure (1 to 15 p.s.i.)

• Generating capacities range from
– 30 cubic feet of acetylene per hour for small
portable
– 6,000 cubic feet acetylene per hour for
medium-pressure generator

Required Oxyacetylene 56
Welding Equipment
• Oxygen regulator
• Acetylene regulator
• Oxygen welding hose

• Acetylene welding hose
• Hose couplings
• Single-purpose cutting torch or welding torch
• Cylinders and cart for portability
• Flash arrestor and check valves (protective
equipment)
• Flint lighter to ignite torch

57
Approved Protective Equipment
• Installed in OAW system to prevent:

– Backflow of oxygen into fuel-gas supply
system
– Passage of flashback into fuel-gas supply
system
– Excessive back pressure of oxygen in fuel-gas
supply system

58
Protective Equipment
• Functions may be combined in one device
or provided by separate devices
– Located in main supply line, head of each

branch line in manifold system, or at each
location where fuel gas withdrawn
• Backflow protection should be provided to
prevent fuel gases from flowing into
oxygen system
• Flashback protection should be provided to
prevent flame from passing into fuel-gas
system

Equipment Setup 59
for Welding
Portable tank
outfits are
mounted on
a truck.

60
Pressure Regulators
• Reduce high cylinder pressure to relatively
low pressure of 0 to 45 p.s.i. used for
welding
• Maintain pressure without variation during
welding
– Flame remains steady and uniform
• Two pressure gauges mounted on body of
regulator
– One shows pressure in cylinder, other
pressure of gas being supplied to torch

61
Pressure Regulators

62
The working pressure is adjusted by means of a hand screw. When this screw is turned to
the left, or counterclockwise, the valve mechanism inside the regulator is shut off, and gas
cannot pass through the regulator to the torch. Turning the pressure-adjusting screw to the
right, or clockwise, presses it against the regulator mechanism. The valve opens, and gas
passes through the regulator to the torch at the pressure shown on the working pressure
gauge. Any pressure can be set up by turning the handle until the desired pressure is
indicated.
63
Safety Precautions
• Inspect all nuts and connections for leaks
• Before opening valve of cylinder to which
regulator has been attached, check pressure

adjusting screw is completely released
• Never attempt to connect acetylene regulator to
cylinder containing oxygen or vice versa
– Do not force connections, and check if tight
• Use regulators only for gas and pressures they
are intended
• Have regulators repaired only by skilled trained
mechanics

64
Regulator Construction
• Internal mechanism of oxygen regulator
• Oxygen enters regulator at left at 2,200
p.s.i. and must leave regulator at desired

pressure for welding – 10 p.s.i.

65
Regulator Construction
• Force that opens valve provided by tension
of spring
• Force that closes valve provided by high

gas pressure from tank
• When two forces balanced, constant flow
of oxygen to torch results
• Designated as single-stage and two-stage
– Single-stage regulators used with manifold
systems
Three Typical Regulator 66
Designs

67
Line Regulator
• Regulator springs made of good grade of
spring steel
• Diaphragm of brass, sheet spring steel,

stainless steel or rubber
• Individual oxygen and acetylene regulators
required at each station when serviced by
line gas system
– Smaller than cylinder regulators
• Not subject to high cylinder pressure

Difference in Internal Construction 68
of a Tank and a Line Regulator

69
Welding Torches
• Apparatus for mixing oxygen and
acetylene in proportions to carry on
welding operation
• Provides handle so welder can hold and
direct the flame
– Two inlet gas connections: oxygen and
acetylene
• Valve controls volume of gas passing through
• Wide range of welding tip sizes

Two Types of Oxyacetylene 70
Welding Torches
• Injector
– Acetylene carried through torch and tip at low
pressure by suction force

• Higher oxygen pressure passing through small
orifice of injector nozzle
– Mixing head and injector integral part of tip
• Equal (balanced-pressure)
– Both gases delivered at equal pressures
– Mixing head separate replaceable unit in body
of torch

71
Injector Torch
Linde Division, Union Carbide Corp.
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.

Balanced-pressure Type 72
Mixer
The two gases are fed in at points
(1) fuel gas and (2) oxygen.
The gases are mixed, beginning at point (3),

throughout the mixing chamber.

73
Injector Type Mixer
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.

Equal-pressure (Balanced- 74
pressure) Torch

75
Self-contained System
Lightweight portable
type work – requires
no outside source
of power
Thermadyne Industries, Inc./Victor Equipment Company

76
Torch Tips
• Size measured by diameter of end opening
– Marked on side of tip
• Most common system: numbers from

000–15
– Larger the number, larger hole in tip and
greater volume of heat provided
• Tips for injector torches provided with
individual mixers so mixer and tip one unit
• Most made of pure drawn copper

77
Safety Precautions
• Do not remove tip with pliers (manufacturers
wrench should be used at all times)
• Never insert or remove tip while tip tube hot

• Keep orifice at end of tip clean at all times
– Clean with tip cleaners
• Do not use tip as hammer
• Protect seat of the tip
©David A. Tietz/Editorial Image, LLC.

78
Gas Economizer
• Provides place to hang torch – safety issue
• Eliminates need of constantly relighting
torch and readjusting flame

• Saves gas Has pilot light
Equipped
When torchwith pilot off
is taken light
hook and passed over
Gases shut off automatically, when the lighted
andlight,
pilot has the
passages
gases through
turn onwhich
and oxygen and
torch relights
torch is hungpass
on the hook.
to acetylene
previous flame before entering torch
setting.

79
Oxygen and Acetylene Hose
• Especially manufactured for purpose
– Strong to resist internal wear
– Flexible so it does not interfere

with welder’s movement
– Abe to withstand
abrasive wear on job

80
Hose Construction
• Three layers of construction
– Inner lining of high grade gum rubber
– Middle layer of rubber-impregnated fabric

– Outside layer made of colored vulcanized rubber
• Plain or ribbed
• Color used for identification
– Green for oxygen
– Red for acetylene
– Black for inert gas and air

81
Hose Size
• Different sizes for different types of welding
and cutting operations
– Depends on amount of gas required, length of

hose used, and pressures needed
• Sizes available: 3/16, 1/4, 3/8, and 1/2 inch
– 3/16 I.D. (inside diameter) hose very flexible,
and light; used for light welding
– 1/2 I.D. used for heavy cutting
• Can be single or double
– Double actually two pieces joined by web
82
Hose Connections
• Standard hose connection
– Nipple inserted in end of hose
– Nut that attaches nipple to torch or regulator

• Threading prevents attaching wrong
head to wrong regulator
– Oxygen coupling has right-hand thread
– Acetylene coupling has left-hand thread
• Nuts marked STD. OXY for oxygen
and STD. ACET for acetylene Thermadyne Industries, Inc.
• Clamps or ferrules connect hose tightly to nipple

to ensure leakproof connection

83
Care of Hose
• Always use hose to carry only one kind of
gas
• Test hose for leaks frequently by

immersing hose at normal working
pressure under water
• Clamp all hose connections or fasten them
securely to withstand pressure of 300 p.s.i.
without leakage
• Repair or replace all hose showing leaks,
burns, worn places, or other defects

84
Care of Hose
• Do not attempt to repair hose with tape
• Handle hose carefully when welding
– Avoid dragging on greasy floor

– Avoid contact with flame or hot metal
– Protect from falling articles or being
stepped on
– Should not be kinked sharply
• Roll up hose and hang it out of the way at
the end of day or job
85
Lighters
• Use friction spark lighter to light welding torch
– Flints easily replaced at small cost
• Safety note: Never use matches

– Puts welder’s hand too close to torch tip where
it may be burned when gases ignite
– Never carry matches in pockets
• May ignite during welding

86
Filler Rod
• Most gas welding done with filler rod
– Provides additional metal to form larger weld
bead
– Many diameters, available in bundles of 50 or
100 pounds and boxes up to 300 pounds net
weight
– 36 inches long
• Steel rods copper coated to prevent rusting
• Some aluminum rods flux coated
– Both steel and aluminum 28 inches long

87
American Welding Society

• Set up AWS classification numbers for
steel gas-welding rods
– RG-65, RG-60 and RG-45

– R indicates welding rod and G indicates gas
welding
– Numbers designate approximate tensile
strength of weld metal (thousand pound per
square inch)
Example: RG-60 is welding rod with tensile strength
of approximately 60,000 p.s.i.

88
Gas Rod Characteristics

• Produce welds of varying tensile strengths
depending upon nature of base metal
• Welds made on alloy steels produce weld

composition between base metal and filler
metal
• Can be used in all positions
– Limited only by skill of welder

Class RG-65 Gas Welding 89
Rod
• Low alloy steel composition
• Used to weld sheet, plate, tubes and pipes
of carbon and low alloy steels

• Produce welds in range of 65,000 to
75,000 p.s.i.

Rod
• Low alloy composition
• Used to weld carbon steel pipes for power
plants, process piping, and other severe

service condition
65,000 p.s.i.
• Used extensively as general-purpose rod
• Highly satisfactory welds in carbon steels,
low alloy steels and wrought iron

Rod
• General-purpose welding rods
• Low carbon steel composition
• Used to weld mild steels and wrought iron

50,000 p.s.i.

92
Fluxes
• Cleaning agent used to dissolve oxides,
release gases, and slag and cleanse metal
surfaces for welding, soldering, and

brazing
• Function of flux
– Combine with oxides to form fusible slag
having melting point lower than metal
• Flows away from weld area
• No one flux satisfactory for all metals

93
Fluxes
• Melting point of flux must be lower than
either metal or oxides formed
• Available as dry powders, pastes, thick

solutions, and coatings on filler rod
• Differ in composition and way they work
according to metals with which they are
used

94
Oxyhydrogen Welding (OHW)

• Form of gas welding once used extensively
– Today have limited use
• Flame produced by burning two volumes of

hydrogen with one volume of oxygen
– Temperature of ~ 4,100ºF
– Almost invisible
• Similar equipment to that used for
oxyacetylene welding
– Need regulator specifically designed for
hydrogen
95
Oxyhydrogen Welding (OHW)
• Relatively low flame temperature

– Used principally in welding metals with low
melting points
– Used extensively in welding of lead
• Thicknesses of lead up to 1/4 or 3/8 inch
• No deposit of carbon

96
Fuel Gases
• Propane, butane, city gas, and natural gas
– Can use standard oxyacetylene welding
equipment
– Need special fuel gas regulator
– Variety of suitable heating and cutting tips
available
• Not suitable for welding ferrous materials
– Oxidizing nature of flame and relatively low flame
temperature
• Used extensively for manual and
mechanized brazing and soldering
operations
97
Air-Acetylene Welding (AAW)

• Air 4/5 nitrogen by volume
– Neither fuel gas nor supporter of combustion
– With acetylene gives lower flame

temperatures
• Total heat content also lowered
• Torches designed to draw in proper
quantity or air from atmosphere
– Acetylene flows through torch 2 to 15 p.s.i.
• Supplied from small cylinder
• Applications: plumbing and electrical
industry

98
Supporting Equipment
• Welding table with either
– Cast iron top, slotted to permit use of hold-
down clamps
– Firebrick top

99
• C-clamps, carpenter clamps,
straightedges, metal blocks, steel square
• Grinders, air-chisels, files, hand chisels

• Cutting torch, gas or electric, for beveling
• Carbon, in form of rods, plates, or paste
• Preheating equipment,
material to provide for
slow cooling
North American Manufacturing Co.

100
• Wire power brush for cleaning scale and
slag
• Some jobs may need no finishing of any

kind
– Others require filing, grinding, drilling, or even
considerable machining

Safety Equipment 101
Welding and Cutting Goggles

• Welders must wear specially designed
goggles
– Protect eyes from infrared and ultraviolet rays,

heat, flying sparks, and particles of hot metal
• Filter lenses make of special optical glass
– Various diameters and tinted green or brown
– Filter out harmful rays
– Minimize effect of glare
– Light, medium, dark shades
• Table 5-3 in text Thermadyne Industries, Inc.

Welding and Cutting Goggles

• Outer lens clear glass or plastic
– 3/64 to 1/16 inch thick
• Light in weight and fit face

• Eye shields
– For welding with electric arc Thermadyne Industries, Inc.
– Have clear cover lens and colored filter lens

– Provide wide range of vision and can be used
over eyeglasses
– Not recommended for welding or cutting
• No protection from the sides

Protective Clothing and Gloves

• Hazards
– Sparks, molten bits of metal and hot scale
• Protect body by apron, shop coat, or

coveralls that resist fire
– High-top shoes and hard hats
• Gloves
– Made from nonflammable material
– Light welding – ordinary canvas glove with cuff
– Keep free from grease and oil

104
Safety Equipment Check Valves
• Permit forward flow of gas and closes

when gas begins to flow in reverse
direction
– One required for acetylene hose and one for
oxygen hose
– May be attached to torch or to regulators
• Reverse flow can be caused by blocked
torch tip, excess gas or oxygen pressure,
lack of pressure or unsafe start-up or
shut-down

105
Flashback Arrestors
• Generally made of sintered metal alloy
• Prevents flame from moving upstream of
arrestor
• Does not protect torch or tip
– Neither does check valve
Best way to assure that accidents don’t happen

is to follow all safety operating procedures.

Internal View of a Check 106
Valve
Prevents
the reverse
flow of gases
Thermadyne Industries, Inc./

Victor Equipment Company

Internal View of a Flashback 107
Arrestor
Thermadyne Industries, Inc./

Victor Equipment Company

General Safety Operating 108
Procedures
Protective equipment, hose, and regulators:
1. Equipment installed and used only in
service for which approved and

recommended by manufacturer.
2. Approved protective equipment installed in
fuel-gas piping.
3. Hose for oxy-fuel gas service shall comply
with Specification for Rubber Welding
Hose, 1958, Compressed Gas Association
and Rubber Manufacturers Association.

Procedures
4. When parallel lengths of oxygen and
acetylene hose taped together, not more
than 4 out of 12 inches shall be covered by

tape.
5. Hose connections shall comply with
Standard Hose Connection Specifications,
1957, Compressed Gas Association.
6. Hose connections shall be clamped so
they can withstand twice the pressure
without leakage (oil-free air or inert gas
used for test).

Procedures
7. Hose showing leaks, burns, worn places,
or other defects rendering it unfit for
service shall be repaired or replaced.

8. Pressure-reducing regulators shall be used
only for gas and pressures for which they
are intended.
9. Use skilled mechanics who have been
properly instructed to repair regulators or
parts of regulators that need repair.

Procedures
10. Gauges on oxygen regulators shall be
marked Use No Oil.
11. Union nuts and connections on regulators

shall be inspected before use to detect
faulty seats that may leak gas when
regulators attached to cylinder valves.

Chapt 5 Gas Weld

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PowerPoint to accompany

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

2. List and describe the properties and

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melting point with gas flame

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fabrication and construction, maintenance

• In nineteenth century various gases tested

• In 1862, acetylene gas produced from

– Later designed low pressure torch (worked on

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

– Oxygen and acetylene

Fuel Gas (ft3) (s/ft2) temp. per ft3 of fuel (ft/s)

Acetylene 1433 12,700 5,420ºF 1.04 17.7

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Various Gas Cylinders

Thermadyne Industries, Inc.

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

• Most abundant chemical element in crust

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

– Separation of water into oxygen and hydrogen

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

– Made of high strength 6061-T6 alloy

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

• Double-seated valve perfectly

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• Gas suppliers fill tanks with varying

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

• When using, do not place cylinders where

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

other fuel-gas cylinders

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

• Generated as result of chemical reaction

Welding Fuel Gas

• Adequate heat content

Acetylene most closely matches all these

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

– Gray, stonelike substance

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

– Others valve located on convex top

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• Two sizes used for welding and cutting

• Do not leave acetylene cylinders on their

– Fusible safety plugs melt at boiling point of

soldering and brazing

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• Strong smell (aid in discovering leaks)

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• Distributed in bulk or steel cylinders

handling acetylene cylinders should be

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Storage, and Operation Safety

1. All portable cylinders used for the storage and

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Storage, and Operation Safety

3. Compressed gas cylinders shall be legibly marked, for

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Storage, and Operation Safety

4. All cylinders with a water weight capacity of over 30

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Storage, and Operation Safety

6. Inside of buildings, cylinders shall be stored in a well-

© 2012 The McGraw-Hill Companies, Inc. All rights reserved.

Storage, and Operation Safety