1.

Gas Welding

1. Gas Welding

Although the oxy-acetylene process has been introduced long time ago it is still applied for its
flexibility and mobility. Equipment for oxyacetylene welding consists of just a few elements, the energy necessary for welding can be transported in cylinders, Figure 1.1.
density in normal state [kg/m3]

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ISF 2002

10.3

370

8.5

330

KW
k

/cm2

natural gas
natural gas

2850
2770

propane

flame temperature with O2

flame efficiency with O2
flame velocity with O2
43 1350
acetylene

3200

510
propane

air

300

490
335
acetylene

200

oxygen

400

oxygen cylinder with pressure reducer

acetylene cylinder with pressure reducer
oxygen hose
acetylene hose
welding torch
welding rod
workpiece
welding nozzle
welding flame

cm

/s

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Properties of Fuel Gas in

Combination with Oxygen

Equipment Components
for Gas Welding

Figure 1.1

oxygen

645

645

600

1
2
3
4
5
6
7
8
9

1.43
0.9

ignition temperature [OC]

1.17

natural gas

1.29

propane

2.0

acetylene

2.5
2.0
1.5
1.0
0.5
0

air

Figure 1.2

Process energy is obtained from the exothermal chemical reaction between oxygen and a
combustible gas, Figure 1.2. Suitable combustible gases are C2H2, lighting gas, H2, C3H8 and
natural gas; here C3H8 has the highest calorific value. The highest flame intensity from point
of view of calorific value and flame propagation speed is, however, obtained with C2H2.

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1. Gas Welding

8
C2H2 is produced in acetylene gas genera-

loading funnel

tors by the exothermal transformation of calcium carbide with water, Figure 1.3. Carbide

material lock

is obtained from the reaction of lime and carbon in the arc furnace.
gas exit

C2H2 tends to decompose already at a pres-

feed wheel

sure of 0.2 MPa. Nonetheless, commercial

quantities can be stored when C2H2 is disgrille

solved in acetone (1 l of acetone dissolves

sludge

approx. 24 l of C2H2 at 0.1 MPa), Figure 1.4.

to
sludge pit
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Acetylene Generator

Figure 1.3

Acetone disintegrates at a pressure of more

acetone

acetylene

than 1.8 MPa, i.e., with a filling pressure of

1.5 MPa the storage of 6m of C2H2 is possible in a standard cylinder (40 l). For gas ex-

porous mass

change (storage and drawing of quantities up

to 700 l/h) a larger surface is necessary,

acetylene cylinder

therefore the gas cylinders are filled with a

acetone quantity :

porous mass (diatomite). Gas consumption

acetylene quantity :

6000 l

during welding can be observed from the

cylinder pressure :

15 bar

~13 l

weight reduction of the gas cylinder.

filling quantity : up to 700 l/h

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Storage of Acetylene

Figure 1.4
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Oxygen is produced by
fractional distillation of

gaseous
cooling

liquid air and stored in cyl-

cylinder

nitrogen
air

inders with a filling presbundle

sure of up to 20 MPa, Fig-

oxygen

liquid
air

oxygen

ure 1.5. For higher oxygen

pipeline
liquid

consumption, storage in a
liquid state and cold gasifi-

tank car
nitrogen
vaporized
cleaning

compressor

separation

cation is more profitable.

supply

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Principle of Oxygen Extraction

Figure 1.5

The standard cylinder (40 l) contains, at a

50 l oxygen cylinder

filling pressure of 15 MPa, 6m of O2 (pres-

protective cap
cylinder valve

sureless state), Figure 1.6. Moreover, cylin-

gaseous

take-off connection

ders with contents of 10 or 20 l (15 MPa) as

p = cylinder pressure : 200 bar

V = volume of cylinder : 50 l
Q = volume of oxygen : 10 000 l

well as 50 l at 20 MPa are common. Gas

consumption can be calculated from the pres-

content control
Q=pV

sure difference by means of the general gas

foot ring

equation.
manometer

liquid

safety valve

vaporizer

filling
connection
user

still
liquid

gaseous

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Storage of Oxygen

Figure 1.6

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1. Gas Welding

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In order to prevent mistakes, the gas cylinders are colour-coded. Figure 1.7 shows a survey
of the present colour code and the future colour code which is in accordance with DIN EN
1089.
old condition

DIN EN 1089

blue

white

old condition

DIN EN 1089

grey

brown
grey

blue (grey)

also of

are

different designs.

Oxygen cylinder connec-

helium

oxygen techn.
yellow

The cylinder valves

brown

red

red

tions show a

right-hand

thread union nut. Acetylene

acetylene
grey

hydrogen
dark green

grey

vivid green
grey

grey

argon-carbon-dioxide mixture

argon
darkgreen

black

grey

grey

carbon-dioxide

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valves

are

equipped with screw clamp

retentions. Cylinder valves
for

darkgreen

nitrogen

cylinder

other

combustible

gases have a left-hand

thread-connection with a

Gas Cylinder-Identification
according to DIN EN 1089

circumferential groove.

Figure 1.7

cylinder pressure

working pressure

Pressure

regulators

re-

duce the cylinder pressure

to the requested working
pressure, Figures 1.8 and
1.9.

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Single Pressure Reducing Valve

during Gas Discharge Operation

Figure 1.8

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At a low cylinder pressure (e.g. acetylene cylinder) and low pressure fluctuations, singlestage regulators
discharge pressure

locking pressure

are applied; at higher cylinder pressures normally

two-stage pressure regulators are used.
The requested pressure is
set by the adjusting screw.
If the pressure increases
on the low pressure side,
the throttle valve closes the

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increased

Single Pressure Reducing Valve,

Shut Down

pressure

onto

the membrane.

Figure 1.9
The injector-type torch consists of a body with valves and welding chamber with welding
nozzle, Figure 1.10. By the selection of suitable welding chambers, the flame intensity can be
adjusted for welding different plate thicknesses.
The special form of the mixing chamber guarantees highest possible safety against
flashback, Figure 1.11.

welding torch
injector or blowpipe

The high outlet speed of

the escaping O2 generates a negative pressure

mixer tube

coupling nut
mixer nozzle
oxygen valve

hose connection
for oxygen
A6x1/4" right

in the acetylene gas line,

in consequence C2H2 is
sucked

and

injector
pressure nozzle
suction nozzle

drawn-in.

C2H2 is therefore avail-

fuel gas valve

welding nozzle

hose connection
for fuel gas
A9 x R3/8 left

able with a very low

pressure of 0.02 up to
0.05 MPa
with

O2

0.3 MPa).

welding torch head

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-compared
(0.2

up

torch body
ISF 2002

Welding Torch

to
Figure 1.10

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1. Gas Welding

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A neutral flame adjustment allows the differentiation of three zones of a chemical reaction,
Figure 1.12:
0. dark core:

escaping gas mixture

1. brightly shining centre cone:

acetylene decomposition
C2H2 -> 2C+H2
1st stage of combustion

2. welding zone:

2C + H2 + O2 (cylinder) -> 2CO + H2

2nd stage of combustion

3. outer flame:

4CO + 2H2 + 3O2 (air) ->

4CO2 + 2H2O
complete reaction:

2C2H2 + 5O2 ->

4CO2 + 2H2O

acetylene
oxygen
acetylene

welding torch head injector nozzle

coupling nut

pressure nozzle

torch body

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Injector-Area of Torch

Figure 1.11

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welding flame
ratio of mixture

welding flame
combustion
welding nozzle centre cone
welding zone
2-5

excess of
oxygen

normal
(neutral)

excess of
acetylene

outer flame

3200C

2500C

1800C

1100C

effects in welding of steel

foaming
spattering

sparking
400C

consequences:
carburizing
hardening

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Temperature Distribution
in the Welding Flame

reducing

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oxidizing
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Effects of the Welding Flame

Depending on the Ratio of Mixture

Figure 1.12

Figure 1.13
welding flame

By changing the mixture ratio of the volumes

balanced (neutral) flame

nozzle size: for plate thickness of 2-4 mm

O2:C2H2 the weld pool can greatly be influ-

discharging velocity and weld heat-input rate: low

2

enced, Figure 1.13. At a neutral flame adjustment the mixture ratio is O2:C2H2 = 1:1. By
reason of the higher flame temperature, an

soft flame

excess oxygen flame might allow faster

discharging velocity and weld heat-input rate: middle

3

welding of steel, however, there is the risk of

oxidizing (flame cutting).
Area of application: brass

moderate flame
discharging velocity and weld head-input rate: high
4

The excess acetylene causes the carburising

of steel materials.
Area of application: cast iron

hard flame
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Effects of the Welding Flame

Depending on the Discharge Velocity

Figure 1.14

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By changing the gas mixture outlet speed the flame can be adjusted to the heat requirements
of the welding job, for example when welding plates (thickness: 2 to 4 mm) with the welding
chamber size 3: 2 to 4 mm, Figure 1.14. The gas mixture outlet speed is 100 to 130 m/s
when using a medium or normal flame, applied to at, for example, a 3 mm plate. Using a
soft flame, the gas outlet speed is lower (80 to 100 m/s) for the 2 mm plate, with a hard
flame it is higher (130 to 160 m/s) for the 4 mm plate.

Depending on the plate thickness are the working methods leftward welding and rightward
welding applied, Figure 1.15. A decisive factor for the designation of the working method is
the sequence of flame and welding rod as well as the manipulation of flame and welding rod.
The welding direction itself is of no importance. In leftward welding the flame is pointed at
the open gap and wets the molten pool; the heat input to the molten pool can be well controlled by a slight movement of the torch (s 3 mm).
Leftward welding is applied to a plate thickness of up to 3 mm.
The weld-rod dips into the molten pool from time to time,
but remains calm otherwise. The torch swings a little.

1,5
welding-rod

flame

welding bead

symbol

flange weld

plain butt
weld

1,0

4,0

3,0

12,0

1,0

8,0

1,0

8,0

lap seam

1,0

8,0

fillet weld

V - weld
1-2
1-2

corner weld

flame

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Flame Welding

Figure 1.15

denotation

1,0

Rightward welding ist applied to a plate thickness of 3mm

upwards. The wire circles, the torch remains calm.
Advantages:
- the molten pool and the weld keyhole are easy to observe
- good root fusion
- the bath and the melting weld-rod are permanently protected
from the air
- narrow welding seam
- low gas consumption

weld-rod

gap
preparations
~
~ s+1

plate thickness
range s [mm]
from to

r=

Advantages:
easy to handle on thin plates

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Gap Shapes for Gas Welding

Figure 1.16

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1. Gas Welding

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In rightward welding the flame is directed
PA

butt-welded seams in
gravity position

onto the molten pool; a weld keyhole is

gravity fillet welds

formed (s 3 mm).
Flanged welds and plain butt welds can be

PB
s

horizontal fillet welds

applied to a plate thickness of approx.

vertical fillet and butt welds

1.5 mm without filler material, but this does

PF
PG

vertical-upwelding position
vertical-down position

PC

horizontal on
vertical wall

not apply to any other plate thickness and

weld shape, Figure 1.16.
By the specific heat input of the different

PE

welding methods all welding positions can be

overhead position

carried out using the oxyacetylene welding

PD

method, Figures 1.17 and 1.18

horizontal overhead position

ISF 2002

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Welding Positions I

Figure 1.17

When working in tanks and confined

spaces, the welder (and all other persons
present!) have to be protected against the

welding heat, the gases produced during

welding and lack of oxygen ((1.5 % (vol.) O2
per 2 % (vol.) C2H2 are taken out from the
PA

ambient atmosphere)), Figure 1.19. The addition of pure oxygen is unsuitable (explosion
hazard!).

PB
PF

A special type of autogene method is flame-

PC

straightening, where specific locally applied

flame heating allows for shape correction of

PG

workpieces, Figure 1.20. Much experience is

PD

needed to carry out flame straightening proc-

PE

esses.
The basic principle of flame straightening de ISF 2002

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pends on locally applied heating in connecWelding Positions II

tion with prevention of expansion. This procFigure 1.18

2005

1. Gas Welding

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ess causes the appearance of a heated zone. During cooling, shrinking forces are generated
in the heated zone and lead to the desired shape correction.

Safety in welding and cutting inside of

tanks and narrow rooms

Flame straightening

welded parts

first warm up both

lateral plates, then belt

Hazards through gas, fumes, explosive mixtures,

electric current
protective measures / safety precautions
1. requirement for a permission to enter
2. extraction unit, ventilation

butt weld
3 to 5 heat sources
close to the weld-seam

3. second person for safety reasons

4. illumination and electric machines: max 42volt

double fillet weld

1,3 or 5 heat sources

5. after welding: Removing the equipment from the tank

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Gas Welding in Tanks and

Narrow Rooms

Figure 1.19

ISF 2002

Flame Straightening

Figure 1.20

2005