Fundamentals of Welding

Oxyfuel Gas Welding (OFW)

Group of fusion welding operations that burn
various fuels mixed with oxygen
 OFW employs several types of gases, which is
the primary distinction among the members of
this group
 Oxyfuel gas is also used in flame cutting torches
to cut and separate metal plates and other parts
 Most important OFW process is oxyacetylene
welding
 Oxyacetylene Welding (OAW)
Fusion welding performed by a high temperature
flame from combustion of acetylene and oxygen
 2mm to 50mm thick metals are welded.
 Flame is directed by a welding torch
 Filler metal is sometimes added
 Composition must be similar to base metal
 Filler rod often coated with flux to clean surfaces
and prevent oxidation
Oxyacetylene Welding
 Acetylene (C2H2)

 Most popular fuel among OFW group because it

is capable of higher temperatures than any other
‑ up to 3480C (6300F)
 Two stage chemical reaction of acetylene and
oxygen:
 First stage reaction (inner cone of flame):

C2H2 + O2  2CO + H2 + heat

 Second stage reaction (outer envelope):

2CO + H2 + 1.5O2  2CO2 + H2O + heat

 Gas Welding

Oxy-Acetylene Welding
Sound weld is obtained by selecting proper size of
flame, filler material and method of moving torch
The temperature generated during the process is
3300ºC
 The flame will only melt the metal.
2mm to 50mm thick metals are welded.
 Gas Welding
 When the metal is fused, oxygen from the
atmosphere and the torch combines with molten
metal and forms oxides, results defective weld
 Fluxes are added to the welded metal to remove
oxides
 Common fluxes used are made of sodium,
potassium. Lithium and borax.
 Flux can be applied as paste, powder,liquid.solid
coating or gas.
Oxy-Acetylene WELDING EQUIPMENT
GAS WELDING EQUIPMENT
 GAS WELDING EQUIPMENT
 Pressure Gauges
 Hoses
 Welding torch
 Types of Flames
Oxygen is turned on, flame immediately changes
into a long white inner area (Feather)
surrounded by a transparent blue envelope is
called Carburizing flame (3000ºC)

Used for hardening the surfaces

 Types of Flames
Addition of little more oxygen give a bright whitish
cone surrounded by the transparent blue
envelope is called Neutral flame (It has a
balance of fuel gas and oxygen) (3200ºC)

Used for welding steels, aluminum, copper and

cast iron
 Types of Flames
If more oxygen is added, the cone becomes
darker and more pointed, while the envelope
becomes shorter and more fierce is called
Oxidizing flame•
Has the highest temperature about 3400ºC

 Used for welding brass and brazing operation

That’s All for Today