9 Main Oxy Acetylene Welding Advantages and Disadvantages | Oxy-Acetylene Welding Process
What is Oxy Acetylene Welding? | Oxy Acetylene Welding Advantages and Disadvantages | How Does Oxy-Acetylene Welding Work? |Oxy-Acetylene Welding Equipment
What is Oxy Acetylene Welding?
Oxy-fuel welding (also known as oxyacetylene welding) refers to techniques that weld or cut metals by using fuel gases (or liquid fuels such as gasoline) and oxygen.
Metals are welded using an oxy-fuel welding flame in oxy-fuel welding. When two pieces of metal are heated to a temperature that creates a shared pool of molten metal, welding occurs.
In most cases, more metal known as filler is added to the molten pool. The choice of filler material is determined by the metals to be welded.
A torch is used in oxy-fuel cutting to heat metal to its kindling temperature. The metal is then exposed to an oxygen stream, which burns it into metal oxide, which flows out of the kerf as dross.
Torches that do not combine fuel and oxygen (rather, combining atmospheric air) are not termed oxy-fuel torches and can usually be distinguished by a single tank (oxy-fuel cutting requires two isolated supplies, fuel and oxygen).
A single-tank torch cannot melt most metals. As a result, single-tank torches are primarily used for soldering and brazing but not welding.
Oxyacetylene equipment is portable and simple to operate. It is made up of oxygen and acetylene gases that are held under pressure in steel cylinders. The cylinders have regulators and flexible hoses that connect to the blowpipe.
Between the hoses and the cylinder regulators, specially designed safety measures such as flame traps are installed.
The flame trap keeps flames from reaching the cylinders caused by a ‘flashback.’ The main sources of flashbacks are failure to purge the hoses and overheating of the blowpipe nozzle.
The operator must wear safety clothes and tinted colored goggles when welding.
Because the flame is less powerful than an arc and emits relatively little UV, general-purpose tinted goggles are adequate protection.
How Does Oxy-Acetylene Welding Work?
Oxy-acetylene welding produces a high-heat, high-temperature flame by burning a fuel gas (often acetylene) combined with pure oxygen.
The base material is melted with the filler rod by passing an oxy fuel gas flame through the tip of the welding torch.
The fuel and oxygen gases are kept in pressurized steel cylinders. The cylinder’s regulators minimize gas pressure.
Gas is passed through flexible hoses, with the welder directing the flow with his torch. After that, the filler rod is fused with the base material. However, melting two metal pieces without the use of a filler rod is also conceivable.
Common Piece of Oxy-Acetylene Welding Equipment
Basic oxy-fuel welding equipment includes the following:
Cylinders: Oxygen and fuel gas are contained in steel pressure cylinders.
Hoses: A nonporous hose transports oxygen and fuel gas to the torch. The oxygen hose is normally green, and the fuel gas hose is usually red, to prevent the wrong hose from being inserted or set up wrongly.
Safety valves: Safety valves control the flow of gas in one direction, preventing gas from flowing back into the incorrect line or cylinder. They also lessen the likelihood of a flashback.
Regulators: Gas flow must be controlled by regulators. Regulators reduce high pressure to a lower operating pressure.
Torches: Torches come in a variety of designs, but all are designed to provide the user complete control over the flame.
Hose couplings: Siamese hoses are molded together hoses that comprise one piece. Hoses can be taped together as well.
Right-hand threaded fittings are used on oxygen lines. Left-hand threaded fittings are used on fuel-gas hoses. After tightening the hose connections, they should not leak.
Flash arrestors, both regulator-mounted and torch-mounted, should be used on oxygen and fuel hoses.
Flash arrestors installed on the regulator prevent flashbacks and backfires from entering the hoses and, potentially, the cylinders.
Oxy Acetylene Welding Advantages and Disadvantages
Advantages of Oxy-Acetylene Welding:
1. Oxy-acetylene welding easy to learn
The main advantage of oxy-acetylene is that it is easy to learn. The process of welding involves little more than learning how to handle the torch and deliver the flame, which many other welding processes require specific skills to perform.
2. Welding can be done outdoors
Unlike other welding processes that need a well-ventilated space, oxy-fuel welding can be done outdoors if there is ventilation.
Oxygen and fuel gas are stored in steel cylinders that have regulators which control the flow of gases into the hose lines.
3. The equipment is cheaper than most other types of welding rigs (e.g., TIG welding)
The cost of oxy-fuel welding equipment is significantly less than that of TIG welding equipment.
4. Oxy-acetylene welding is useful for household repairs/projects
The main advantage of oxy-acetylene is the fact that it can be used to do household repairs and DIY projects.
It can also be used to cut metals, which makes it suitable for tasks such as repairing shower rods and cutting metal furniture.
5. Oxy-acetylene welding equipment is more portable
Another key advantage of oxy-acetylene is that it can be used for mobile projects.
6. Large pieces of material can also be “flame-cut” using oxy acetylene equipment
Oxy acetylene equipment can also be used to cut out large pieces of material that have accumulated on the floor.
Disadvantages of Oxy-Acetylene Welding
1. Oxy-acetylene welding is not suitable for some metals
Oxy-acetylene welding equipment is not suitable for some metals because it does not have enough heat output to melt them.
These materials include stainless steel and aluminium, so welding them would be very ineffective, if it was possible at all.
2. Requires utmost care
While oxy-acetylene welding itself is not dangerous, the equipment can still become dangerous.
While an oxy-acetylene torch makes it easier to work with, if something unfortunate happens during a project, such as the cylinder leaking or overheating, it could be extremely dangerous and cause serious damage to the welder and the surrounding area.
3. Oxy-acetylene equipment can be bulky
The oxygen and fuel gas cylinders are quite bulky, which can make them cumbersome to use. They also tend to be large, which means that they will not be easy to move from one place to another.
Oxyacetylene Welding FAQs
How does Oxyacetylene welding works?
Oxyacetylene welding, often known as gas welding, is a procedure that relies on the combustion of oxygen and acetylene.
When these ingredients are combined in the proper proportions in a hand-held torch or blowpipe, a relatively hot flame with a temperature of around 3,200 degrees Celsius is created.
The chemical action of the oxyacetylene flame can be modified by varying the volume ratio of oxygen to acetylene.
There are three main flame settings: neutral, oxidizing, and carburizing.
What are the benefits of oxy-acetylene (OA) welding?
One of the various types of welding is oxy-acetylene (OA) welding. It is incredibly versatile, and with enough skill and practice, you can use it to weld almost any metal.
The oxy-acetylene flame, in reality, burns at 6000 °F and is the only gas flame hot enough to melt all commercial metals.
The premise of oxy-acetylene welding is simple: two pieces of metal are joined, and the touching edges are melted by the flame with or without the inclusion of filler rod.
What are the principles of oxy-acetylene welding?
The oxy-acetylene welding procedure combines oxygen and acetylene gas to create a high-temperature welding flame.
This temperature is hot enough to melt most metals. In nature, the chemical interaction between acetylene and oxygen is exothermic.
What are some hazards of Oxy-Acetylene Welding?
The primary hazards of oxy-acetylene welding are related to the acetylene and oxygen cylinders and the chemical nature of the combustion reaction.
It can result in serious injury and is potentially life threatening.
How do you know if your oxygen regulator is bad?
A defective oxygen regulator could result in a number of problems during oxy-acetylene welding. For example, it could produce a lower-than-expected flow rate when the gas is turned on, which affects the welding quality, or nothing at all because of a blocked needle valve.
If you suspect that your regulator might be faulty, there are some simple tests that you can perform to check for problems.
How do you do Oxy Acetylene Welding?
Oxy Acetylene welding is a type of welding that uses a flame to melt two pieces of metal together.
Although it sounds like a very easy process, oxy acetylene welding can be tricky.
However, with enough practice and expertise, you can make it look as if you were doing nothing at all.
What metals can the oxy-acetylene process weld?
All commercial metals can possibly be welded with oxy-acetylene welding.
Low-alloy steel, low-carbon steel, wrought iron, and cast iron are among the metals that can be welded with oxy-acetylene.
What is the Temperature of Oxy-Acetylene Welding?
Welding and cutting are both done with acetylene. Acetylene welding is referred to as oxy-fuel cutting or gas cutting.
This process is used to cut or weld materials that demand temperatures as high as 3,500 degrees Celsius (6,330 degrees Fahrenheit).
Acetylene has the ability to produce the brightest flame of any other gas.
How thick can you weld with oxy acetylene?
Oxy-acetylene systems are mostly applied for combining metal sheets or metal plates with thicknesses ranging from 2mm to 50mm.
When the material thickness exceeds 15 mm, an extra filler metal, such as a welding rod, is added.
How is the oxy acetylene welding process?
In the oxy acetylene welding process, a welding torch is used to melt the edges of two pieces of metal. The torch heats up metal rods that are then thrown onto the surface of the two edges to be welded.
The high heat melts both sides of the metal together. This process works on all metals except stainless steel or aluminum.
The process of oxy-acetylene welding is referred to as “flame cutting”, because it is a mixture of flame heating and metal oxidizing.
The metal oxidizing process is used to separate the metal at the joint when the flame temperature rises above 1,500 degrees Celsius (2,732 degrees Fahrenheit).
At this temperature level, the metal flows freely.
Once you have the correct ratio of oxygen to acetylene selected, then you can start welding with your oxy acetylene welder.