VELEUILITE U SLAVONSKOM BRODU

Struni studij Proizvodnog strojarstva

SEMINAR


GAS WELDING






Miroslav Cigleneki











Slavonski Brod, 2014



VELEUILITE U SLAVONSKOM BRODU

Struni studij Proizvodnog strojarstva













SEMINAR

Oxyacetylene welding



Kolegij: Engleski jezik

Miroslav Cigleneki

Matini broj: 691S

Mentor: prof. Jasna Vuji










Slavonski Brod, 2014.
Miroslav Cigleneki; Zavarivanje mjeavinom plina
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CONTENTS
1 INTRODUCTION .................................................................................................................. 3
1.1 Welding in general .......................................................................................................... 3
1.2 Gas welding .................................................................................................................... 3
2 WELDING EQUIPMENT .................................................................................................... 4
2.1 Welding equipment ......................................................................................................... 4
2.2 Bottles of oxygen and acetilen ........................................................................................ 4
2.3 Reduction valves and check valves ................................................................................ 5
2.4 Gas torch, handle and gas supply ................................................................................... 7
2.5 Welder's equipment ........................................................................................................ 8
3 GAS WELDING ................................................................................................................... 9
3.1 Apllication of the procedure .......................................................................................... 9
3.2 Additional materials and fluxes .................................................................................... 10
3.3 Gas welding Tehnology ................................................................................................ 11
4 CONCLUSION ..................................................................................................................... 12



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1. INTRODACTION
1.1 Welding in general
Today is over 100 welding procedure applied in practice including soldering,
ISO 4063.
Welding processes can be divided into melting (heating) and welding with
pressure.
Welding procedures often are classified by energy source:
1. Electric ( Electrical resistance, electrical beam, el. onion)
2. Chemical ( flame, explosives,...)
3. Mechanical ( presure, friction, ultrasound)
4. And others
1.2 Gas welding
It is one of the oldest and most used welding.
Gas welding is a method of joining metals by melting and stiffening
( hardening) primary and (if necessary) additional metals using flame
The flame is obtained by burning gas with oxygen
The most commonly used gas is carbon-based gases; methane (CH4 ), methyl
acetylene (C3H4 trade name MAPP), acetylene (C2H2), propane (C3H8),
propene (C3H6), butane (C4H10) and hydrogen (H2).
The amount of heat libereted combustion and the maximum flame temperature,
depending on type of fuel gas as well as a mixture with oxygen.
In order to achive better combustion, fuel gas and oxygen are from special
presurized containers- bottles

Tablica 1. Maksimalne temperature kod razliitih plinova
acetylene propane butane methane propene methyl hydrogen
t
max
(C) 3087 2526 2300 2538 2865 2927 2655
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2. WELDING EQUIPMENT
2.1 Welding equipment
Gas welding equipment consists of a bottle of oxygen and acetylene, reduction valves, check
valves, inlet hose, handle with adjustable jets and burners, as well as auxiliary devices Figure
2.1. Welder that could weld with knowledge of welding must have a mask for welding, for this
type of welding are usually glasses scratch resistant lenses and fireproof equipment.


Figure 2.1 Gas welding equipment

2.2 Bottles of oxygen and acetylen
Cylinders for technical gases have appropriate standards.
Oxygen bottles are 40 liters in volume that can be stored 6 m3 of a pressure of 150 bar
on a temperature of 20 C. And it is assumed that the oxygen in these conditions behaves like an
ideal gas. To calculate the amount of gas remaining in the tank (for example, if the bottle 80 bar
oxygen, the amount of residual oxygen is 80x40 = 3200 l). Oxygen bottle is colored in blue or a
blue stripe on the 2/3 height. Oxygen is produced by fractional distillation of air (rarely
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electrolysis of water because it is expensive procedure). The basic principle of fractional
distillation is that the air is first converted to a liquid state (which is achieved by pressurizing to
40 bar and cooling to -200 C). If liquid air is then heated, nitrogen will evaporate at -196 C,
remains the only oxygen (which at -183 C). Specific weight of oxygen at a temperature of 20C
and a pressure of 1,013 bar is 1.43 kg/m3.

Figure 2.2 Bottle gas and oxygen with equipment on a trolley

Acetylene cylinders are painted in white or brown. Acetylene bottle dissolves in acetone,
because acetylene as unsaturated hydrocarbon is very explosive at elevated pressure. Acetylene
cylinders are filled to 15 bar. Acetylene gas is from a group of unsaturated hydrocarbons.
Dissolved in water at a ratio of 1: 1, acetone and 1: 25 at atmospheric pressure and a temperature
of 20 C. Solubility of acetylene in acetone increases with pressure and decreases with
increasing temperature. The bottle of acetylene, which is a volume of 40 liters, at a pressure of
15 bar and a temperature 20 C fit 6 m3 acetylene. At the exit of the bottle is set regulator
pressure (gauge), which lowers the pressure of acetylene to values below 1.5 bar (if the output
from a bottle of acetylene pressure exceeds 1.5 bar may create gas bubbles and connecting with
the air, which can cause gas explosion).

2.3 Reduction valves and check valves
The operating pressure is much lower than the pressure in the bottles, on the bottles are
putting pressure regulating valves for oxygen and acetylene Figure 2.3. Both pressure regulators
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with two manometers, one for the pressure in the bottle, the other for working pressure. The
working principle of reducing valve is the same, the only difference is in the way of connecting
to the bottle, because of the possibility of wrong connection to the bottle. The difference is in the
range of measurement - with oxygen gauges are up to 300 bar (pressure in the bottle) or 16 bar
(working pressure), and with acetylene to 40 bar and 2.5 bar operating pressure.
,
Figure 2.3 Manometer

Particular attention should be to the handling of a reducing valve for oxygen. How to contact
with oxygen grease, oil or other similar substances may cause an explosion. Because of
difference of pressure of oxygen the manometer can be frozen.

Figure 2.31 Check valves on the gas and oxygen regulators


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2.4 Gas torch, handle and gas supply
The burners can receive the necessary mixture of oxygen and acetylene. The main parts of
the burner are: handle with connections to oxygen 1/4 and Acetylene 3/8" left, valve for
regulating the flow of oxygen, valve for fine control flow of acetylene, and many sizes of burner
solid and flexible.

Figure 2.4 Torch Welding and Cutting Equipment

Under pressure power burners are classified based on the pressure in the mixture nozzle.
Burners with low pressure if the pressure of the mixture is lower then
the gas pressure
Burners with high pressure if the pressure is greater than the pressure of
gases
According to the regulation of the flow:
Changing the flow in very small limits
And in which the regulation is possible
In addition to the properties of the burners are classified by size and nozzles to be selected
according to the thickness of the base material. They are marked with numbers from 1 to 8



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2.5 Welder equipment
Gas welder must be protected therefore can use all prescribed protective equipment such as:
Protective caps
Safety glasses with dark glasses
Protective gloves for welder
Protective clothing and aprons
Safety shoes with steel cap


Figure 2.50 Glasses for gas welding











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3. GAS WELDING
3.1 Aplication of procedure
The main advantage of gas welding is the ability to control that welder have over
speed of using heat, the temperature in the oxidation zone of welding and weld metal.
In addition, the shape and size of the weld can be controlled better, because the additional metal
is introduced regardless of the source of heat. The advantages of the process include the low cost
of the equipment.
Flame gas is also used for cutting, soldering, welding, preheating,
heat treatment and forming operations easier, such as bending and straightening.

Depending on relation of acetylene and oxygen we have: reduction (lack of oxygen),
neutral (complete combustion) and cutting (excess oxygen). Although theoretically a mixture of
oxygen and acetylene 1:1 in practice under neutral flame is considered O2: C2H2 = (1.1 1.2):1.
Excess oxygen is used for combustion of the surrounding gas.


Figure 3.10 Example of neutral flame


Figure 3.12 Example of exesses of oxygen
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Figure 3.13 Example of reduction flame

3.2 Additional materials and fluxes
Additional materials are delivered in the form of wires and rods. In the case of welding of low
carbon and low-alloy steel filler material is in the form of a rod length of 1000 mm. Wire weight
40 kg, standard diameters: 2; 2.5; 3.25; 4; 5; 6.3 mm. Designation of additional material consists
of two parts: the base (the letter P) and supplemental (letter O, Z, Y, or the number of 1 to 6).
The wires are coated with a thin layer of copper to protect it from corrosion.

Table 1 Marking wire for gas welding of steels
simbol Z Y 1 2 3 4 5 6
Rm [MPa] <340 340 400 430 470 510 550 590
A5,65 [%] <14 - 14 18 22 26 30 -
KV [J] 30 - 30 60 90 120 150 -



Figure 3.20 The wires for gas welding







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3.3 Gas welding tehnology
Prescribing technology include gas welding torch and pitch selection, choice of strings
welding, as well as the choice of techniques and welding parameters (flow rate, thickness of
wire, welding speed, consumption of acetylene, oxygen and welding wire).
The size and strength of the burner is selected based on the type and thickness of the base
material strength burner measured flow of acetylene (l / h). Position burner significantly affects
the percentage flame heat recovery, as well as the protection of the melt. Heat recovery is
paramount in holding the torch perpendicular to the spot welding, Figure 3.30. This position
burner go deeper and is narrower weld. Deviation from the vertical position of the burner gives a
much shallower and wider weld, which is favorable for welding thin materials.

In gas welding commonly used burner gradients are 60 80 , except in very thin layers, where
they are used less inclination, 45 60 , Figure 3.30.




Figure 3.30 The influence of slope in gas welding



a) Left welding techniques b) right welding techniques

Figure 3.31 Gas Welding Techniques

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1. CONCLUSION
Gas (acetylene) welding is increasingly used, but only in a building with mechanical
installations, installation of heating, cooling, gas, vacuum, compressed air, etc.

Recently every newly built facilities especially offices, workshops, halls and shopping
centers using steel pipes smaller profile which means that the gas welding is the best solution,
and because of the low cost of welding equipment as well as the possibilities of welds in very
inaccessible places via mirrors or small proximity to a wall or corner gas welding is the best
solution.
Certainly for large deformations in the material is not used for large diameter pipes and
where is required great precision, and is also quite slow welding.




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