Fusion Welding
Gas Welding:
Metal joining process in which the ends of pieces to be joined
are heated at their interface by producing coalescence with one or
more gas flames (such as oxygen and acetylene), with or without
the use of a filler metal
Gas welding is a Fusion welding process.
It is done by combustion of fuel
gases with the help of oxygen which
forms a concentrated flame of high
temperature.
This flame directly strikes the weld area and melts the weld
surface and filler material.
The melted part of welding plates diffused in one another
and create a weld joint after cooling.
This welding method can be used to join most of common
metals used in daily life.
Types of gas welding :
Types of gases (Fuels):
Based on the combination of the
▪ Acetylene (C2H2) gases used :
▪ Propylene (C3H6)
➢ Oxy acetylene gas welding (most
▪ hydrogen (H2) common type)
▪ propane (C3H8)
➢ Air- acetylene gas welding
▪ natural gas (CH4 + H2).
➢ Oxy-hydrogen gas welding
Oxy acetylene welding
Principle:
➢ Uses a high temperature flame from the combustion of
acetylene (C2 H2 ) with oxygen with O2
➢ Liberation of heat due to exothermic reactions.
Combustion takes place in two
stages. Secondary stage:
Primary stage : 4 CO+2H2 + 3O2 = 4 CO2 +2
• C2 H2 + O2 = 2 CO+H2 + 448 H2O + 812 kJ/mol
kJ/mol (18.75 MJ/m3) Heat (35.77MJ/m3) Heat
Temperature –approx 3200 0C
• Most concentrated heat • Heat is spread over large area
• Concentrated cone • Temperature apprx.1200 to
2000 0C
Equipment:
Equipment …..
Oxygen Cylinder:
Oxygen is supplied by a oxygen cylinder. A black line is used to
indicate oxygen cylinder.
•Pressure 13.8 MPa to 18.2 MPa
•Volume 7m3 gas
•Weight 80 kg full condition
Fuel Gas Cylinder:
Gas cylinder is filled either by acetylene gas, hydrogen gas, natural
gas or other flammable gas.
Normally these cylinders have Maroon line to indicate it. The fuel
gases passes through it.
Acetylene is most commonly used as fuel gas in gas welding.
Equipment …..
Acetylene cylinder : Cylinder or generator can be used.
Acetylene is not stable above 2 bar (200kPa) hence it is stored at low pressure
in a dissolved form inside the cylinder.
Storage: 80% porous material + liquid acetone (Can absorb 420 times of
its volume at 1.75 MPa)
Acetylene mole
The porous material may be charcoal/asbestos/Calcium Silicate
Acetylene gas consumption is at a pressure of 15 bars (1.5 MPa) lesser than
rate of release (one seventh of the capacity of cylinder per hour).
Acetylene generators are of two types:
1. Carbide to water : Carbide dropped into water; very high Yield (about
95%)
2. Water to carbide method : Water is periodically fed into calcium carbide;
Lower yield (85 to 90%).
CaC2 + 2H2O = C2H2 + Ca(OH)2
Equipment …..
Welding Torch:
Both the fuel gas and oxygen at suitable pressure fed through
hoses to the welding torch.
There are valves for each gas which control the flow of gases
inside the torch.
Both gases mixed there and form a flammable mixture.
These gases ignite to burn at the nozzle. The flame flow through
nozzle and strikes at welding plates.
Equipment …..
Cylinder valves: To regulate the flow of gases.
Specific coding - left hand threads for combustible gases and
right hand threads for non combustible gases.
Pressure regulators: To regulate the pressure
Hoses for transportation of gases
Nozzle or tip: Gas mixtures pass just prayer to their ignition
tip size determines the flow rate of gas mixtures
Other accessories: Goggles and Gloves:
These are use for safety purpose of welder. It protects eyes and
hand from radiation and flame of fire
Working
In this process all the equipment are
connected carefully.
The gas cylinder and oxygen cylinder
connected to the welding torch through
pressure regulators.
Now regulate pressure of gas and oxygen
supplied to the torch where they properly
mixed.
The flame is ignited. Take care the tip of
torch is pointing downward.
Working …
Flame is controlled through valves situated
in welding torch.
The flame is set at natural flame or
carburizing flame or oxidizing flame
according to the welding condition.
Now the welding torch moved along the
line where joint to be created.
This will melt the interface part and join
them permanently.
Types of flames in gas welding
There are three basic flame types:
1. Neutral Flame (balanced)
Neutral Flame:
2. Oxidizing (excess oxygen) and
3. Carburizing (excess acetylene)
•Oxidizing Flame:
•Carburizing Flame:
Types of flames in gas welding ….
Neutral Flame:
-Equal volume of acetylene and oxygen.
-Obtains additional oxygen from the air
and provides complete combustion.
-Generally preferred flame.
The neutral flame has a clear, well-
defined, or luminous cone indicating
that combustion is complete
There are two clearly defined zones in the
neutral flame. Commonly used to weld:
▪Mild steel
▪ The inner zone consists of a luminous ▪Stainless steel
cone that is bluish-white. ▪Cast Iron
▪ Surrounding this is a light blue flame ▪Copper
envelope or sheath. ▪Aluminum
Types of flames in gas welding ….
Oxidizing Flame:
▪ Excess oxygen.
▪ When the flame is properly adjusted, the inner cone is pointed
and slightly purple.
▪ An oxidizing flame can also be recognized by its distinct
hissing sound.
▪ The temperature of this flame is approximately 3482ºC at the
inner cone tip.
Oxidizing welding flames are
commonly used to weld
these metals:
•Zinc
•Copper
•Manganese steel
•Cast iron
Types of flames in gas welding ….
Carburizing Flame:
▪ Excess acetylene, the inner cone has a feathery edge
extending beyond it.
▪ The reducing or carburizing flame can always be recognized
by the presence of three distinct flame zones.
1. Clearly defined bluish-white
inner cone,
2. White intermediate cone
indicating the amount of
excess acetylene, and
3. A light blue outer flare
envelope.
▪ It has a temperature of approximately 3149ºC at the inner
cone tips.
Gas Welding Techniques
Welding techniques depends on
o Material being welded
o Size and shape of the material
o Properties of the joint
Two techniques:
1. Leftward (forward) welding or forehand welding
2. Right ward (backward) welding or back hand welding
Leftward welding
Torch moves in the direction of nozzle (tip)
i.e., welding stars at right and moves towards
left.
Preheating the metal before white cone melts
the metal.
Generally used for thin materials (up to 5 mm
thick)
60-700
More uniform weld and less cost; less skills.
Used on steel for: flanged edges welds 30-400
Un-beveled plates up to 3mm
Beveled plates up to 5mm
Cast iron and non-ferrous metals.
Rightward welding
▪ Welding starts at left and moves towards right.
▪ The outer blue flame directs on the already
welded joint.
▪ Complete annealing & stress relieving takes place.
▪ Suitable for thick materials (thickness>5 mm).
▪ Improved Mechanical properties.
▪ Reduced gas consumption.
When using welding rod it should be kept at a
proper distance to get it preheated.
More distance cool reduces the
puddle temperature
Less distance tip melts and hence the
molten metal would be blown away. This results 40-500
uneven bead and poor penetration 30-400
Used for: steel plates exceeding 5mm thickness.
steel plates over 5mm, beveled to 30o, giving a V-
weld of 60o
Advantages and Disadvantages of Gas Welding
Advantages:
1. It is easy to operate and dose not required high skill operator.
2. Equipment cost is low compare to other welding processes
like MIG, TIG etc.
3. It can be used at site.
4. Equipment’s are more portable than other type of welding.
5. Easy for maintenance & repair.
6. It can also be used as gas cutting.
Advantages and Disadvantages of Gas Welding ……
Disadvantages:
1. Slow metal joining rate i.e., very low welding speed (Longer time)
2. It provides low surface finish. This process needs a finishing
operation after welding.
3. Gas welding have large heat affected zone which can cause
change in mechanical properties of parent material.
4. Higher safety issue due to naked flame of high temperature.
5. It is Suitable only for soft and thin sheets.
6. Not suitable for welding reactive materials.
7. No shielding area which causes more welding defects.
Applications of Gas Welding
1. It is used to join thin metal plates.
2. It can used to join both ferrous and non-ferrous
metals.
3. Gas welding mostly used in fabrication of sheet
metal.
4. It is widely used in automobile and aircraft
industries.
Gas cutting
Using conventional general purpose cutting machines, it is difficult
to cut thicker materials (more than 40 mm) and
to cut metals into different shapes
Hence gas cutting is used.
Material thickness: 3 mm 22 meters and
Special controls are possible
Principle: Iron and steel can be heated approx.800 – 1000 0C where
they readily gets oxidized.
Oxygen at higher pressure approx.300KPa will be supplied so that
iron gets oxidized, the metal melts and blown away causing the cut
(Kerf).
Gas cutting ….
Equipment: oxy acetylene gas cutting is similar to gas
welding except some differences in torch tip.
The cutting tip size depends on the thickness of the plate.
If larger size is used -----kerf width increases
smaller size is used ----- material cannot be cut.
Preheating will be done by oxy acetylene flame approx.800 –
1000 0C and then oxygen jet is released.
The reactions occur are:
3Fe+2O2 = Fe3O4 + 6.67 MJ/Kg of iron for cutting
Other reactions
2Fe+O2 = 2FeO+3.18 MJ/Kg of iron for preheating
4Fe+3O2 = 2Fe2O3+4.9MJ/Kg of iron for preheating
Gas cutting ….
Advantages, Disadvantages and Applications of Gas Cutting
Advantages of Gas Cutting
▪ High speeds
▪ No electric power is required
▪ Both straight and contours are possible
▪ Higher thickness metals can be cut
Disadvantages of Gas Cutting
▪ Suitable for materials which are readily oxidized
▪ Difficult to get clean cut
▪ Surface finish is rough and dimensional accuracy is poor.
Applications
▪ For cutting large plates
▪ Cutting broken are worn-out components
▪ Cutting rises in castings etc.
Thank You
