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Gas Welding
Topics
Overview
Welding (also called fusion welding) is the process of heating two or more materials
(usually metals) to a melting point where they can coalesce, sometimes with additional
material (a third metal) called filler. When the heating is provided by gas, naturally, the
term used is “gas welding.” Oxyacetylene and oxy-MAPP (methylacetylenepropadiene)
welding are two types of gas-welding processes. Both require a gas-fueled torch to
raise the temperature of two similar pieces of metal to the fusion point that allows them
to flow together. A filler rod is used to deposit additional metal as necessary to merge
the two base materials. The gas and oxygen must be mixed to correct proportion and
pressure in the torch, and you can adjust the torch to produce the type of flames
appropriate for the metal being welded.
This chapter presents information on the equipment and materials used in gas welding,
as well guidance on the operation and maintenance of oxyacetylene and oxy-MAPP
equipment. In addition, it will recommend welding techniques for both ferrous and
nonferrous metals.
Objectives
When you have completed this chapter, you will be able to do the following:
1. Describe the purpose and components of the OXYGAS welding equipment.
2. Describe the operation and maintenance of OXYGAS welding operations.
3. Identify the different types OXYGAS welding techniques.
Prerequisites
None
This course map shows all of the chapters in Steelworker Basic. The suggested training
order begins at the bottom and proceeds up. Skill levels increase as you advance on
the course map.
Gas Cutting
Introduction to Welding
Figure 5-1 — Typical oxygas welding rig similar to oxygas cutting rig.
In addition to the basic equipment shown, you also will use much of the same auxiliary
equipment as presented in Chapter 4 Gas Cutting, and the same safety equipment
identified in Chapter 3 Introduction to Welding, for example, tip cleaners, cylinder trucks,
clamps, strikers, gang wrench, and holding jigs. Safety apparel such as goggles, gloves,
as well as leather aprons, sleeves, and leggings are essential, and you should wear
them as appropriate for the work being performed (Figure 5-2).
Each manufacturer assigns its own arrangement for classifying tip sizes, but typically
they are designated by a number system which corresponds to the diameter of the hole
in the tip.
A. True
B. False
2.1.0 Operation
A properly made gas weld has a consistent appearance that shows a uniform deposit of
weld metal and complete fusion of the sidewalls forming a good joint (Figure 5-9).
Orifice size will determine the quantity of fuel-gas and oxygen fed to the flame, and by
extension, it determines the amount of heat the torch tip can produce: the larger the
orifice, the greater the heat.
If you use a torch tip with too small an orifice, you will not be able to generate enough
heat to bring the metal to its fusion temperature.
If you use a torch tip with too large an orifice, you are likely to produce poor welds for
these reasons:
1) The weld is made too fast.
NAVEDTRA 14250A 5-11
2) You have difficulty controlling the melting of the filler rod.
3) You cannot control the appearance.
Therefore, the quality of the weld is unsatisfactory.
For practice purposes, use an equal-pressure torch with the filler welding rod sizes and
the tip sizes shown in Table 5-2; they should give you satisfactory results as you
develop your hands-on skills.
Table 5-2 — Welding Rod Sizes and Tip Sizes Used to Weld Various Thickness of
Metal
Pressures
Metal Thickness Diameter Welding Tip Drill Size
Oxygen Fuel-Gas
Rod*
* Sizes listed in this table are approximate and will give satisfactory results. The size of the piece welded
will govern the choice. When welding small pieces, use the smaller size tip and welding rod. When
welding larger pieces, use the larger size tip and welding rod.
You use the same procedure for oxygas welding WROUGHT IRON as you do for low-
carbon or mild steel; however, you need to keep several points in mind (Figure 5-17).
3.6.1 Copper
You can oxygas weld pure copper, but where high-joint strength is a requirement, use
DEOXIDIZED copper (copper that contains no oxygen). Use the following guidance.
• Use neutral flame.
• Use flux.
• Preheat to 500°F to 800°F.
• Use larger size tip for welding.
o A larger tip supplies more heat to maintain the required temperature at the
joint.
• Post-welding, cool slowly.
Other than the extra volume of heat required, the technique for welding deoxidized
copper is the same as for steel.
CAUTION
Safeguard against zinc poisoning by doing welding outdoors or by wearing a
respirator, or by both, depending on the situation.
3.6.6 Lead
To oxygas weld lead, you need to use special tools and special techniques.
When you weld lead or lead alloys, wear a respirator approved for protection against
lead fumes.
WARNING
LEAD FUMES ARE POISONOUS.
Flux is not required, but you must ensure the metal in the joint area is scrupulously
clean by shaving the joint surfaces with a scraper and wire brushing them to remove all
oxides and foreign matter.
You can use a square butt joint if you are welding in the flat position, but for all other
positions, you need to use a lap joint with edges overlapping from ½ to 2 inches,
depending upon the thickness.
• Use special lightweight fingertip torch, with tips ranging from 68 to 78 in drill size.
• Use neutral flame with gas pressure ranging from 1½ to 5 psig, depending on
thickness.
o Flame length will vary from 1½ to 4 inches depending upon gas pressures.
• Use soft, bushy flame when welding in horizontal and flat positions.
• Use more pointed flame when welding in vertical and overhead positions.
• Ensure filler metal is same composition as base metal.
• Manipulate flame in semicircular or V-shaped pattern to control and distribute
molten puddle.
• Make separate, individual, tiny segment welds.
o Flick torch away upon completion of each semicircular or V-shaped
movement.
• Make joints in thin layers.
• Do not add filler metal on first pass; add on all subsequent passes.
Summary
Gas welding is just one of many skills you need to practice and become proficient in as
a Steelworker. Depending on the characteristics and thickness of the material you have
for an assigned task, you may determine that gas welding is the preferred method for
either repair or fabrication. This chapter presented information about the necessary
NAVEDTRA 14250A 5-30
equipment and identified how similar it is to gas cutting equipment in setup, use, and the
gases utilized. It also provided instructions on how to operate and maintain the
equipment in good working order with proper tip cleaning tools. Lastly, it offered gas
welding techniques with recommendations about when to use the forehand or backhand
technique relative to type of weld and specific metal. With this guidance, you should be
able to set up the equipment, adjust the pressures, select the appropriate filler metal to
match the base metal, and practice/practice/practice until you can demonstrate your
capabilities and proficiencies in gas welding to yourself and your supervisors.
3. In a low-pressure torch, the fuel pressure in pounds per square inch (psig) is
_____.
A. 1 psig or less
B. 2 to 3 psig
C. a constant 5 psig
D. greater than 7 psig
4. What device(s) control(s) the volume of oxygen and fuel-gas burned at the torch
tip?
A. nitrogen
B. gasoline
C. oxygen
D. helium
A. True
B. False
8. The copper coating on steel filler rods enables the rods to _____.
9. Which factor determines the proper diameter of filler rod to use for gas welding
two steel plates?
10. Which factor determines the type of filler rods to use in oxygas welding?
11. (True or False) Welding tip sizes are standardized among manufacturers.
A. True
B. False
12. What mistake have you most likely made when you have difficulty controlling the
melting of the welding rod, the welds are being made too fast, and their
appearance and quality are unsatisfactory?
13. What factor dictates the adjustment you must make to the flame after igniting a
welding torch?
A. Neutral
B. Carburizing
C. Oxidizing
D. Normalizing
A. Neutral
B. Carburizing
C. Oxidizing
D. Normalizing
A. Neutral
B. Carburizing
C. Oxidizing
D. Normalizing
17. What is the first corrective step you should take when needle valves fail to shut
off when hand tightened in the usual manner?
18. When there is a leak around the torch valve stem, you should tighten the packing
nut or repack it if necessary. For repacking, NEVER use oil. Instead, you should
use only _____.
A. dry packing
B. the packing recommended by the manufacturer
C. heavy-weight packing
D. granulated packing
19. You must remove deposits of _____ regularly to ensure good performance of
welding tips.
A. Insert a drill one size larger than the orifice opening into the tip end.
B. Insert a tip drill into the seat opening and twist until penetration can be
made at the tip-end opening.
C. Place emery cloth, grit side up, on a flat surface and rub the tip end over it
until the tip is back to its original condition.
D. Use a bench grinder to square off the end of the tip, then drill out the
orifice.
A. Mill
B. Pillar
C. Square
D. Taper
22. When forehand welding, you point the flame in the direction of travel and hold the
tip at about a _____ angle.
A. 15°
B. 30°
C. 45°
D. 60°
24. When backhand welding, you point the flame away from the direction of travel
and hold the tip at about a _____ angle.
A. 15°
B. 30°
C. 45°
D. 60°
25. For which of the following reasons should you use the backhand method instead
of the forehand method when welding plates thicker than 1/8 inch?
A. It uses less welding rod and results in less puddling of molten metal.
B. It requires less motion of the rod and torch tip and increases welding
speed.
C. It results in better control of large puddles of molten metal and achieves
more complete fusion at the root of the weld.
D. All of the above
27. Which factor is an advantage of using multilayer welding instead of single layer
when welding thick plate and pipe?
28. (True or False) Sheet metal melts easily and does not require special edge
preparation.
A. True
B. False
29. On what thickness of plate do you begin to make a slight root opening between
the parts to get complete penetration?
30. What size plate requires beveled edges 30 degrees to 45 degrees and a root
opening of 1/16 inch?
31. What action must you take to relieve stresses developed when oxygas welding
low-alloy steels?
33. (True or False) When you oxygas weld cast iron, you must preheat the entire
weldment to between 750°F and 900°F. After completing the weld, you must
postheat the weldment to between 1100°F to 1150°F to relieve stresses.
A. True
B. False
34. Which characteristics apply to the method of joining a light stainless steel sheet
by oxygas welding?
35. To what temperature range should you preheat the joint area when you oxygas
weld deoxidized copper?
A. 100°F to 300°F
B. 300°F to 500°F
C. 500°F to 800°F
D. 800°F to 900°F
36. Assuming the same welding process and same part thickness, compared with
the technique for joining steel parts, the technique for joining deoxidized copper
calls for the use of a/an _____.
37. What type of rod is used for welding brass by the oxygas process?
A. Lead
B. Steel
C. Silicon-copper
D. Silicon-bronze
39. You must wear a respirator to guard against poisonous fumes when you weld
_____.
A. silver
B. aluminum
C. lead
D. brass
40. What type of welding rod should you use to minimize cracking when gas welding
wrought aluminum alloys?
A. 1100
B. 3003
C. 4043
D. 5511
A. steel
B. iron
C. copper
D. titanium
42. For which reason do you use a flux when welding aluminum alloy?
43. Edge notching is a recommended procedure for oxygas butt welding aluminum
plate because it _____.
A. 300°F
B. 500°F
C. 700°F
D. 900°F
45. (True or False) The forehand method of welding is preferred for aluminum
alloys.
A. True
B. False
46. What action should you take to reduce the possibility of heat-treatable aluminum
alloys cracking during the welding process?
47. Which requirement must be met to complete a successful weld when oxygas
welding pipe?
48. (True or False) For welding pipe, the backhand technique is preferred
because it produces faster melting of the base metal surfaces, allows a smaller
bevel to be used, and results in a savings of 20% to 30% in welding time, rods,
and gases.
A. True
B. False
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