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Gas Welding Torches

A welding torch sometimes called a “blowpipe” and a cutting torch sometimes incorrectly
called a “burning torch” are each designed for a specific purpose. These torches are somewhat
similar in construction, but a cutting torch is provided with a separate control valve to regulate
an oxygen jet for the cutting. These torches come in a variety of sizes and designs depending
on their intended use.
The oxyacetylene welding torch is used to mix oxygen and acetylene gas in the proper
proportions and to control the volume of these gases burned at the welding tip. Torches have
two needle valves, one for adjusting the flow of oxygen and the other for adjusting the flow of
acetylene. In addition, they have a handle/body, two tubes - one for oxygen and one for
acetylene, a mixing head, and a tip. Welding tips are single-hole copper-alloy tips are attached
to a torch handle equipped with a mixer that mixes the fuel with the oxygen, much like a
carburetor in a car mixes the gas and air. Welding tips are made from a special copper alloy
with less than 60% copper, which dissipates heat and are available in different sizes to handle a
wide range of plate thicknesses. Welding tips usually produce positive pressure higher than 1
pound per square inch and are used at equal pressures of acetylene and oxygen. Cutting tip
design is based on the flame characteristics of the fuel gas used, as well as the intended use.
Cutting tips come in one-piece and two-piece styles
The body and head of torch are forged from extruded brass rod so as to ensure leak proof
product which is free from blow holes or any casting porosity thus assuring total safety and gas
economy. Torches are made of various materials, including brass, aluminum, and/or stainless
steel. The various parts are threaded and silver-brazed together.
Use of nozzle mixing technology assures no back fire thus making chances of flashback very
remote. The tubes for oxygen and fuel gas are of tough seamless stainless steel and are silver
soldered to the forged brass body and forged nozzle head for leak proof joints.
In 1900, Edmond Fouche, a Frenchman, invented a high pressure acetylene torch. He later
designed a low pressure torch that worked on the injector principle. There are two types of
welding and cutting torches commonly used.
1. Injector Type - Also known as low pressure torch
2. Positive Pressure Type - Also known equal pressure, medium pressure, balanced
pressure and high pressure torch
Positive Pressure Type
In a positive-pressure torch oxygen and fuel gas are mixed in the torch and are burned at the
end of the torch tip. In the medium-pressure torches, the acetylene is burned at pressures from
1 to 15 psi. The torch consists of four main parts
1. Body
2. Hand torch valves
3. Mixing chamber
4. Tip
The design of positive pressure torches requires that oxygen and fuel gas be supplied under
enough pressure to force them into the mixing chamber. This means that positive pressure
torches require cylinder or manifold gas supplies, and cannot be used with low pressure gas
generators.
The mixing chamber is usually located inside the torch body, although some torches
incorporate the mixing chamber in the torch tube. Gases are fed to this chamber through two
brass or stainless steel tubes leading from the torch valves. The torch valves are generally either
a needle-and-seat or ball-and-seat design.
The size and design of the mixing chamber depends on the size of the torch. The orifice, or
hole drilled in the tip, must be an accurate size. Orifices and the chambers should never be
abused. The tip size or number is normally stamped on the tip. The tip number indicates the
orifice size and the relative volume of gases that it will allow to flow through the tip. The tips
are usually made of copper, but some tips are nickel-plated to reflect heat and stay cooler. In
some texts the torch tip size is indicated by number of drill sizes.

Equal-pressure torches are often called balanced-pressure torches because the fuel gas and the
oxygen pressure are kept equal. Operating pressures vary, depending on the type of tip used.
Most industrial oxy fuel torches are of equal pressure design. The big advantage of the equal
pressure torches is that you have total control of the Acetylene/oxygen ratio. This is important
when you want to have a very carburizing or oxidizing flame. Because of the design of the
mixing chamber, the equal pressure torches have a significantly higher flow rating. This is
important when running large "rosebuds" heating attachments. This style mixer works well
with acetylene, propylene, propane, natural gas, and modified propane such as MAPP. The
equal pressure torch is safer than the injector torch, since equal gas pressures are used and it is
less likely to get a flashback

If you use Acetylene as fuel gas, use an equal pressure torch. If the job at hand requires use of
large size heating attachments "rosebuds" or cutting nozzles, stick to equal pressure torches.
The equal pressure welding torch is most commonly used in practice. Equal pressure torch is
Light and simple in operation. It suffers less from back fire. It does not need an injector. Flow
rate of both the gases can be controlled individually. Flow rate of acetylene does not suffer
from the flow rate of oxygen.
Injector Type Torch
In this type of torch fuel gas pressure is 0.07 bar (1 psi) or less. The oxygen pressure ranges
between 0.7 - 2.8 bar (10 - 40 psi) depending on the size of the torch tip. A jet of relatively high
pressure oxygen produces the suction necessary to draw the fuel gas into the mixing head. It
takes low pressure acetylene from acetylene generator.
The high velocity of the oxygen causes suction and low pressure acetylene is sucked in through
the pipe, into the mixing chamber. An advantage of low pressure torch is that small fluctuation
in the oxygen supply produces a corresponding change in the amount of acetylene drawn this
makes volume of the two gases constant.
An injector welding torch looks much like a positive-pressure torch. However, the internal
construction of an injector torch is somewhat different. The chief characteristic of an injector
torch is its ability to operate using very low acetylene pressure. In general, the acetylene
pressure remains practically constant regardless of the size tip or thickness of the metal being
welded. The ability of this torch to operate on low acetylene pressure has certain advantages. If
acetylene is being supplied by a low-pressure acetylene generator, which supplies acetylene at a
pressure of approximately 0.25 psig (1.7kPa), an injector torch must be used. An injector torch
also has the advantage of being able to draw out the last remnants of acetylene from source
which a positive pressure torch is unable to do thus reduces waste.
The oxygen line enters the mixing chamber through a jet which is surrounded by the acetylene
passage. As the oxygen flows from the jet, it draws (injects) the acetylene along with it.
Handling the valves and the other operations of the torch is much the same as with the
positive-pressure type torch. It should be noted that the oxygen pressure used in these torches
is considerably higher than with the positive-pressure type torches. Always follow the torch
adjustments recommended by the torch manufacturer. The materials used to construct
injector-type torches are usually the same as those materials used to construct positive-pressure
torches
The advantages of injector torches are that you do not have to adjust the fuel gas pressures
only the oxygen. Only a small amount of pressure is needed in the fuel gas. This is important if
you are using natural gas. The injector torch will actually suck open the fuel gas regulator
diaphragm even when the adjusting screw is backed way out (closed) and the gauges will show
zero pressure and yet you have a flame. The disadvantages of injector torches are that it is not
optimized for acetylene. It cannot run the very large heating attachments
How to Properly Light, Adjust and Shut Down an Oxy–Acetylene Torch
Lighting, adjusting and shutting down an oxygen-acetylene torch is easy – especially when
following the proper procedures. In addition to these easy to follow instructions, you must
always be sure to follow the torch manufacturer's operating procedures.
First - before you attempt to light the torch follow these checks:

1. Make sure regulator pressure adjustment screws are backed out!


2. Make sure torch valves are closed!
3. Stand away from front of regulator
4. Separately and slowly open the oxygen and acetylene cylinder valves
5. Adjust regulator p/a screws to tip pressure settings
6. Open/close torch valves separately and fine tune pressure settings on regulators
7. Depress cutting lever and adjust pressure if necessary

Lighting and adjusting the torch (with a positive/equal pressure mixer):

1. Separately purge both oxygen and fuel gas lines


2. Open fuel gas valve 1/2 turn
3. Ignite flame with striker
4. Increase fuel gas flow until flame leaves end of tip and no smoke is present
5. Decrease until flame goes back to tip
6. Open oxygen valve and adjust to neutral flame
7. Depress oxygen lever and make necessary adjustments

Shutting down the torch (with a positive/equal pressure mixer):

1. Close oxygen torch valve


2. Close fuel gas torch valve

If the torch/regulators and gases are done being used for a while, follow these procedures:

1. Close oxygen and fuel gas cylinder valves


2. Separately purge oxygen and fuel gas lines
3. Make sure all regulator gauges read 0
4. Back out regulator pressure adjustment screws!
5. If you are using in a commercial environment, report any damage, etc. to your
supervisor

A flashback occurs when the flame burns back inside the torch and causes a shrill hissing or
squealing. The oxygen valve should be closed first, thus eliminating the oxygen to the fire
(flashback). Never shut off the fuel first as this gives the flashback the opportunity to seek other
fuel such as soot or other flammable material and continue to burn. The torch should be
allowed to cool. Before relighting, blow oxygen through the torch tip for a few seconds to clear
out any soot that may have formed in the passage

Most manufacturers direct that oxygen goes off first and then fuel gas. If you do it the reverse
way it will often *pop,* When it pops carbon is drawn down into the holes at the tip and
reduces performance and the same carbon soot may burn back inside the torch to constitute a
flashback

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