OXY-FUEL GAS CUTTING

DEFINITON :
A group of cutting processes used to several metals
by means of the chemical reaction of oxygen with the
metal at elevated temperature. The necessary
temperature is maintained by mean of gas flames
obtained from the combustion of specified fuel gas
and oxygen
( OFC-A; OFC-H; OFC-N; OFC-P)

OXY-FUEL GAS WELDING and

BRAZING

WELDING
Material joining process used in making weld
Weld : A localized coalescence of metals or nonmetals
produced either by heating the materials to suitable
temperatures, with or without the application of pressure , or by
the application of pressure alone and with or without the use of
filler material
Oxy-fuel gas welding ( OFW ): A group of welding process
which produces coalescence by heating materials with an oxy
fuel gas flame or flames, with or without the application of
pressure and with or without the use of filler metal

OXY-FUEL GAS WELDING AND

BRAZING
FUSION WELDING :
Any welding process or method which uses fusion to complete the
weld.
Fusion : The melting together of filler metal and base metal (
substrate ), or base metal only, which result in coalescence.
Depth of fusion : The distance that fusion extends into the base
metal or previous pass from the surface melted during welding

OXY-FUEL GAS WELDING AND

BRAZING
TORCH BRAZING (TB) :
A brazing process in which the heat required is furnished by a
fuel gas flame.
TORCH SOLDERING (TS) :
A soldering process in which the heat required is furnished by a
fuel gas flame.

OXY-FUEL GAS PROCESSES

1. PRINCIPLES OF PROCESS
2. GASES

3. EQUIPMENTS
4. WELDING PROCEDURE AND TECHNIQUES

5. SAFETY

PRINCIPLES OF PROCESSES
DEFINITION
The process involves melting the base metal and usually a filler
metal,using a flame produced at the tip of welding torch. Fuel
gas and oxygen are combined in the proper proportions in side
a mixing chamber which may e part of the welding tip
assembly. Molten metal from the plate edges, and filler metal, if
used, intermix in a common molten pool and coalesce upon
cooling.
Flame Temperature of a fuel gas will vary according to the
oxygen-to-fuel ratio.
Combustion Intensity takes into account the burning velocity
of the flame, the heating value of the mixture of oxygen and
fuel gas, and the area of the flame cone issuing from the tip.

GASES
( 1.02 6 )

OXYGEN

FUEL GASES

Manufacture of oxygen
Properties
Storage of oxygen
Pressure and temperature
Content of oxygen
Oxygen consumption
Unloading volume of oxygen
Type of fuel gases
Requirements of fuel gases
Explosion limits
Permissible gas consumption rate
Summary of fuel gases

GASES

ACETYLENE
Manufacture
Storage of acetylene
Content os an acetylene cilinder

PROPANE GAS
What is propane gas
Special handling and safety
Others

EQUIPMENTS

1. GAS CYLINDERS
2. CYLINDERS VALVES
3. CYLINDER PRESSURE REGULATORS
4. SAFETY EQUIPMENTS
5. WELDING HOSES
6. WELDING TORCH

EQUIPMENTS

GAS CYLINDERS
Color-code and cylinder connections
Transportation ( handling ) of gas cylinders
Storage of gas cylinders

CYLINDER VALVES
Standards

CYLINDER PRESSURE REGULATORS

Function
Operating instruction
Leak test of a pressure connection
Gauges

EQUIPMENTS

SAFETY EQUIPMENTS
Check valves
Flashback arrestors

WELDING HOSES
Design of hoses
Distinguishing signs
Length of hoses
Attachment of hoses
Handle of hoses and connections
Gaskets

EQUIPMENTS
TORCHS

Design of torch
Correct blowpipe attacment
Injector blowpipe
Special attachment
Maintenance and services

WELDING PROCEDURE AND

TECHNIQUE

OXY-ACETYLENE FLAME

Combustion of the oxy-acetylene flame

Type of welding flame
Flame intensity
Flame distance
Backfire
Reverse flow (backflow)
Flashback
Remedies

INITIATION OF THE GAS WELDING PLANT

Igniting and regulating the welding flame
Extinguishing the flame

WELDING PROCEDURE AND

TECKNIQUE

OXY-FUEL GAS WELDING TECKNIQUE

LEFTWART WELWDING (FOREHAND WELDING)

RIGHTWART WELDING (BACKHAND WELDING)
TWO-OPERATOR TECKNIQUE
SUMMARY OF GAS CONSUMPTION

JOINT PREPARATION

WELDING POSITIONS
TYPES OF JOINT
TYPES OF WELD
TYPES OF GROOVE

WELDING PROCEDUR AND

TECKNIQUE

DISCONTINUITIES ( DEFECTS )
Shapes /Visual Inspection
Destructive Test
NDT

THE OTHER APPLICATIONS OF

OXY-FUEL GAS PROCESSES
APPLICATION
OTHER APPLICATION
COATING/CLADDING
SURFACING/SPRAYING
BUILDING UP WELDING

CLEANING
HEATING

HARD FACING
ACID RESIST. FACING
BRONZE FACING

THE OTHER APPLICATION . . . . .

APPLICATION
HEATING
Flame Straightening
Stress Relieving
Flame hardening
Tempering

B1.13
CUTTING AND OTHER EDGE
PREPARATION PROCESSES (1)
EDGE PREPARATION METHODS
EDGE PREPARATION
THERMAL CUTTING
OXY- FUEL GAS CUTTING

LASER CUTTING

OXYGEN ARCCUTTING
PLAZMA ARC CUTTING

ARC CUTTING

AIR CARBON ARC CUT.

OTHERS

CUTTING AND OTHER EDGE

PREPARATIONS PROCESSES(2)

PREPARATION METHODS
SHEARING
SAWING
MILLING

MECHANICAL C.

WATER JET CUTTING

GRINDING
PLANING

THERMAL CUTTING
CLASSIFICATION AND SELECTION OF METHOD
( 1.14-5 )

APPLICATIONS OF THERMQAL CUTTING

( 1.14 6 )

COMPREHENSIONS FOR CUTTING

( 1.14 7 )

OXY-FUEL GAS CUTTING (1)

( 1.14 8-26 )

FONDAMENTALS OF THE PROCESS ( ADD. )

PROCEDURE OF CUTTING (1.14 8-10)
SUITABILITY OF MATERIALS ( 1.14 10-12 )
CUTABILITY OF STEEL ALLOY (1.14 12-13 )
EQUIPMENTS ( 1.14 13-18 )
HARDENING OF THE CUT SURFACE ( 1.14 - 18 )
QUALITY OF THE CUT SURFACE ( 1.14 19-21 )
FAULTS IN THE CUTS AND THEIR CAUSES ( 1.14
21-26 )

OXY-FUEL GAS CUTTING (2)

FONDAMENTALS OF THE PROCESS

( ADD. )

DEFINITION:
OFC is a group of cutting processes used to sever metals by
mean of the chemical reaction of oxygen with the base metal
at elevated temperatures. The necessary temperature is
maintained by mean of gas flames obtained from the
combustion of a specified fuel gas and oxygen.
PRINCIPLES OF OPERATION:
OFC begins by heating a small area in the surface of the metal
to the ignition temperature with an oxy-fuel gas flame. A
cutting oxygen streams then directed at the preheated spot ,
causing rapid oxidation of the heated metal and generating
large heat. This heat supports continued oxidation of the
metal as the cut progresses.

OXY-FUEL GAS CUTTING (3)

PROCEDURE OF CUTTING
STARTING AT THE EDGE OF PALATE
PIERCING

SUITABILITY OF MATERIALS FOR OFC

The ignition temperature for the burning of the metal at the cut
must be lower than its melting temperature of the parent metal.
Melting temperature of the oxide layer (slag) must be lower than
the melting temperature of the parent metal.
The burning slag must be of low viscosity.
He thermal conductivity of the material must be low.
Materials must have good cut-ability.

CUTTABILITY OF ALLOYS STEEL

OXY-FUEL GAS CUTTING (4)

IPMENTS

UTTING ATTACHMENTS
LAME CUTTER NOZLES

DENING OF THE CUTT SURFACE

LITY OF THE CUT SURFACE

UDGED BY
EPENDING UPON

Cutter nozzle
Intensity of flame
Purity of cutting oxygen
Flame adjustment
Type of flame
Manipulation of blowpipe
Material

OXY-FUEL GAS CUTTING (5)

FAULS IN CUTTING AND THEIR CAUSES

Nozzle too close

Cutting speed too low
Heating flame too large
Nozzle too far from the plate
Faulted nozzle
Cutting speed too high

B 1.16
SOLDERING AND BRAZING

DEFINITION
ADVANTAGES
CLASSIFICATION
WORKING PROCEDURE
HEATING TIME AND SOLDERING
TEMPERATURE
FLUXES
SOLDERS
APPLICATION

SOLDERING AND BRAZING

DEFINITION (1)
Soldering (S): A group of welding processes which
produces coalescence of materials by heating them
to a suitable temperature and by using a filler metal
having a liquidus not exceeding 8400 F and below of
the solidus of the base metal. The filler metal is
distributed between the closely fitted faying
surfaces of the joint by capillary action.
Brazing (B) : A group of . . . . . . Above 8400
F
and below of . . . . . . . . . . . . . ..

SOLDEERING AND BRAZING

DEFINITION (2)
Braze welding : A welding process variation in which a
filler metal, having a liquidus above 8400 F and below a
liquidus of the base metal is used. Unlike brazing , in
braze welding the filler metal is not distributed in the
joint by capillary action.
Solder : A filler metal used in soldering which has a liquidus
not exceeding 8400 F.
Brazing filler metal : The metal which fills the capillary gap ang
has a liquidus above 8400 but below the solidus of the base metal.

SOLDERING AND BRAZING

DEFINITION (3)
Brazer : One who performs a manual or semiautomatic
brazing operation.
Brazement : An assembly whose component part are joinned by
brazing.
Brazing operator : One who operates machine or automatic
brazing equipment.
Brazeability : The capacity of metal to be brazed under the
fabrication conditions imposed into a specific suitably design
structure and to perform satisfactorily in the intended service.

SOLDERING AND BRAZING

CLASSIFICATION (1)
WORKING TEMPERATURE
Soft soldering (below 4500 C )
Hard soldering / brazing ( 4500 9000 C )
High temperature soldering ( above 9000 C )

FORM OF SOLDERING JOINTS

Joints design for welding and soldering
Soldering gaps
Preparing of soldering ( brazing ) gap

SOLDERING AND BRAZING

CLASSIFICATION (2)
METHODS OF SOLDERING

Bit soldering
Flame soldering ( torch soldering/brazing = TS/TB)
Furnace brazing
Dip soldering ( molten chemical and molten metal )
Induction brazing
Resistance brazing

SOLDERING AND BRAZING

CLASSIFICTION (3)
FEEDING OF SOLDER BRAZING
ALLOY ( BRAZING FILLER METAL)
Soldering with put on solder ( molten chemical
bath system)
Soldering with deposit solder
Dip soldering (molten metal bath system )

SOLDERING AND BRAZING

WORKING PROCEDURE AND
PRINCIPLES OF OPERATION (1)
PROCEDURE OF WORKING

Pre-cleaning
Apply the flux
Assembling the components
Heating the part
Attaining the working temperature
Wetting of solder
Cooling and cleaning

SOLDERING AND BRAZING

WORKING PROCEDURE AND PRINCIPLES OF
OPERATION (2)
PRINCIPLE OF OPERATION (BASIC STEPS)

Choosing the solder and flux

Cleaning
Fixing the gap (clearance )
Heating
Treatment of the soldered/brazed joint

SOLDERING AND RAZINNG

HEATING TIME AND SOLDERING
TEMPERATURE (1)

Preheating time
Soaking time
Stop time
Re-cooling time
Total time

SOLDERING AND BRAZING

HEATING TIME AND SOLDERING
TEMPERATURE (2)

Soaking temperature
Soldering temperature range of the flux
Working temperature
Brazing temperature
The temperature to which the base metal is heated to enable the
filler to wet the base metal and form a brazed joint

BRAZING AND SOLDERING

FLUXES (1)
DISTINCTION IS MADE FOR DIFFERENT SOLDERING
TEMPERATURES

Soldering/brazing temperature 7500-11000C

Soldering/brazing temperature 5500-8000C
Soldering/brazing temperature 5000-6000C
Soldering/brazing temperature 2000-3000C
EXAMPLES

SOLDERING AND BRAZING

FLUXES (2)
FUNCTION OF THE FLUXES

Preventing oxidation
Exclusion of air from the brazing face
Pushing away the air from the solder gap (capillary attraction)
Promoting the fluidity of the brazing solder
Promoting the wetting action
Flux indicates the working temperature
Flux prevents oxidation of the soldering stick

SOLDERING AND BRAZING

SOLDERS or BRAZING FILLER METALS
(BRAZING ALLOYS)
A filler metal used in soldering which has liquidus not
exceeding 8500 F
DISTINGUISHED ACCORDING TO THE WORKING
TEMPERATURE :
SOFT SOLDER
HARD SOLDER (BRAZING FILLER METAL OR ALLOYS)

Brazing alloys for aluminum

Silver hard solders
Copper phosphorus hard solders
Copper hard solders

SOLDERING AND BRAZINNNG

BRAZING 0R BRAZE WELDING OF STEEL
Application

BRAZING AND SOLDERING OF ALUMINUM

Advantages

BRAZING AND SOLDERING OF COPPER

Soft soldering
Hard soldering