Many types of welding processes are used for fusing metal. The process of fusing metal includes two or more metal pieces combined into a single metal by merging and melting their surfaces. Welding processes like TIG welding, MIG welding and others are used. However, among them Oxy-Acetylene welding is a flexible and widely used process to fuse the metals.
The process of Oxy-Acetylene welding forms a flame which melts the metal for cutting and joining, by combining two gasses, namely acetylene and oxygen. Oxy-Acetylene is used in different applications. For instance, the aircraft industry, repair works, sheet metal fabrications and joining steels, cast iron, aluminum, copper, nickel etc.
As this process has a variety of uses, now the question is, what equipment is used to make this process versatile. Hence, in today’s blog, we will explore different types of equipment used in the Oxy-Acetylene welding process with their purpose, uses and others.
Types of Equipment Used in Oxy-Acetylene Welding
Oxy-Acetylene welding (also known as Oxyfuel welding) uses a wide variety of equipment that ensures both the safety of the welder and quality of the weld. These are mentioned below:
1. Welding Torches
Welding torches are an essential equipment used in the Oxy-Acetylene welding process. The main function of this element is to produce a high-temperature flame which mixes with acetylene and oxygen gasses to ignite the flame. It also helps welders to control the shape, temperature and size of the flame for different tasks like performing heavy repairs or welding thin materials etc.
The torch’s high temperature allows it to be used in various metalworking tasks such as cutting metals and heating materials. There are also different types of welding torches available to use in specific applications. For instance, single-stage, multi-stage and semi-automatic or automatic torches.
Some of the primary components of an Oxy-Acetylene welding torch are as follows:
Nozzle:
Depending on the desired flame application and profile, nozzle comes in various configurations and sizes such as straight, tapered or curved.
The nozzle mixes oxygen and acetylene gasses in a precise ratio, and then these gasses are expelled from the nozzle and ignited using flame which is directed at the workpiece for cutting and welding.
Control Valves:
Control valves are typically separate for each of the gas. This component helps to adjust the flow rate of acetylene and oxygen gasses to control the flame’s intensity and size.
Handle:
Handle is made of heat resistant materials to provide grip for the welder to control the flow and pressure of each gas. It is important to prevent excessive gas combustion and maintain a stable flame by the handle’s regulator that ensures the gas pressure is consistent.
Ignition Mechanisms:
Few torches come with built-in igniters, however others require a spark lighter. This mechanism helps to produce the welding flame through the mixture of oxygen and acetylene gasses.
There are also other components of the welding torch which is optional. For instance, tip adapters, swivel connectors etc.
2. Hoses
Hoses are a crucial component in the Oxy-Acetylene welding process to safely deliver the gasses from the oxygen and acetylene cylinders to the welding torch. Hoses are made of durable, heat resistant flexible materials such as rubber or synthetic materials like polyurethane or neoprene.
The diameter of the hoses ranges from ¼ to ½ inch. Hoses are attached to the gas cylinders and torch by couplings and fittings to avoid any damage. These fittings have specific thread to ensure correct installation, right hand for oxygen and left hand for acetylene.
Most importantly, color coding ensures welders to easily and quickly identify the correct hose for the particular material, in order to prevent the risk of error. Oxygen is usually blue and acetylene is red in color.
3. Pressure Regulators
Pressure regulators, also known as gas regulators are used to control and maintain the flow of gasses from cylinders to the welding torch. They produce a steady flow of gas by reducing the cylinder pressure to a suitable working pressure.
There are generally two types of pressure regulators, single-stage regulator and two-stage regulator. In addition, there are also two gauges that work separately. The first gauge works by determining the high pressure of the gas in the cylinder and the second gauge works by lowering the pressure of gas fed to the torch.
4. Oxygen and Acetylene Cylinders
Oxygen and acetylene cylinders are considered as the fundamental equipment of Oxy-Acetylene welding as they offer necessary gasses for the welding process. The purpose of using an oxygen cylinder is to produce the gas flame and support the combustion of acetylene. This cylinder is black painted with gray/white shoulder and is made of mild steel or alloyed steel with a weight of 66 kg. The pressure of this cylinder can be as high as 300 bar. The oxygen cylinder and regulator have a right hand thread.
On the other hand, the purpose of using acetylene cylinders is to generate a high-temperature gas flame when it reacts with oxygen to melt and join metals. This cylinder is maroon in color and is made of steel with a weight of 86 kg. The acetylene regulator and cylinder have a left hand thread. It is estimated that this cylinder has an approximate pressure of 15 bar.
Note: Check the cylinders must have a label to determine which type of gas they contain. This information will help you to ensure proper storage and handling of the cylinder to avoid any accident or injuries.
5. Fire Extinguisher
Fire extinguisher is an important equipment while performing Oxy-Acetylene welding. Acetylene is known as a highly flammable gas, whereas oxygen makes the fire burn more intense as it supports combustion. The type of extinguisher which the industry regulations and guidelines have recommended is class B fires and class C fires.
Class B fires are used in gasses and flammable liquids, while class C fires are used in electrical fires.
6. Welding Rod
Welding rod, also known as filler metal or rod which acts as an additional material to weld the joint. It creates a strong and durable bond between the base metals. This rod is used to provide the overall strength and durability of the weld.
Welding rod is generally made of the similar properties and composition as the base metal. Few of the common materials used in welding rods are stainless steel, bronze, aluminum and so on. It is important to keep these rods away from grease, non-metallic properties, dust and other contamination. Monitor the flame of Oxy-Acetylene as it may affect the welding process and weld quality.
In addition, the welding rod should be selected properly and stored to contribute to a successful welding in the Oxy-Acetylene welding process.
7. Ignition Tool
Ignition tool produces the welding flame by igniting the gas mixture of acetylene and oxygen. It needs careful handling to ensure efficiency and safety. Different types of tools which are used in Oxy-Acetylene welding are piezoelectric lighter, flint striker, automatic ignition etc.
Ignition tool ensures that the acetylene gas which is flowing through the torch does not cause ignition due to static electricity or spark. It also ensures a consistent flame quality and temperature.
Precautions
Here are some of the precautions you should follow while performing Oxy-Acetylene welding.
- Ensure that all the connections are secure and check if there are any damage, leaks or cracks found in torch components.
- Use and wear proper PPE (personal protective equipment) with safety glasses, gloves and a face shield.
- Check the valves when it is not in use. Avoid dropping and rough handling and use proper handling techniques.
- Use appropriate fittings and regulators for the cylinders.
- Check the direction of the flame.
- Make sure that the cylinders are not overdue for testing. Hence, check them regularly for corrosion or leaks.
- Ensure proper ventilation and understand the process of Oxy-Acetylene.
Conclusion
In summary, welders may accomplish high-quality welding more safely and precisely by knowing how to maintain and using these equipment. Oxy-Acetylene welding may be made even more effective by receiving the right training and following the safety procedures, which guarantees both a secure work environment and good results.
Hence, the above list represents the core equipment used in Oxy-Acetylene process and may vary depending on the specific application, welding technique and metal type.