D06-002 - Fundamentals of Gas Cutting and Welding - US

Fundamentals of Gas Cutting and
Welding
Course No: D06-002

Credit: 6 PDH
A. Bhatia
Continuing Education and Development, Inc.
P: (877) 322-5800
info@cedengineering.com
www.cedengineering.com
Fundamentals of Gas Cutting and Welding – D06-002
FUNDAMENTALS
OF
GAS WELDING & CUTTING
GAS WELDING AND CUTTING
Oxy-fuel welding, commonly referred to as oxy welding or gas welding is a process of

joining metals by application of heat created by gas flame. The fuel gas commonly
acetylene, when mixed with proper proportion of oxygen in a mixing chamber of welding
torch, produces a very hot flame of about 5700-5800°F. With this flame it is possible to
bring any of the so-called commercial metals, namely: cast iron, steel, copper, and
aluminum, to a molten state and cause a fusion of two pieces of like metals in such a
manner that the point of fusion will very closely approach the strength of the metal fused.
If more metal of like nature is added, the union is made even stronger than the original.
This method is called oxy-acetylene welding.
Cutting with the oxy-fuel process is just the opposite from of welding. Oxy-fuel cutting
uses acetylene and oxygen to preheat metal to red hot and then uses pure oxygen to
burn away the preheated metal. Because this is achieved by oxidation, it is only effective
on metals that are easily oxidized at this temperature. Such metals are mild steel and
low allow steels. Oxy-fuel cutting can be used to cut thicknesses from 2/8″ to up to 12″.
Traditionally oxy-fuel processes are used for brazing, fusion welding, flame hardening,
metalizing, soldering, stress relieving, cutting and bending. The primary uses today are
welding, brazing and cutting. This course describes the basic concepts of oxy-fuel
welding and cutting including what equipment and safety precautions are needed.
Chemistry of Oxy Acetylene Process
The most common fuel used in welding is acetylene. It has a two stage reaction; the first
stage primary reaction involves the acetylene disassociating in the presence of oxygen
to produce heat, carbon monoxide, and hydrogen gas.
2C2H2 + 2O2 = 4CO + 2H2 + Heat ---------- (1)
A secondary reaction follows where the carbon monoxide and hydrogen combine with
more oxygen to produce carbon dioxide and water vapor.
4CO + 2H2 + 3O2 = 4CO2 + 2H2O + Heat--------- (2)
When you combine equations (1) and (2) you will notice that about 5 parts of oxygen is
necessary to consume 2 parts of acetylene
2C2H2 + 5O2 = 4CO2 + 2H2O + Heat ----------- (3)
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Or we can say about 2.5 parts of oxygen is necessary to achieve complete combustion
of acetylene. In operation, one part of oxygen is supplied through the torch and the
remaining 1.5 parts is obtained from the surrounding air atmosphere (secondary
reaction). When the secondary reaction does not burn all of the reactants from the
primary reaction, the welding processes produces large amounts of carbon monoxide,
and it often does. Because of the need for supplemental oxygen from the atmosphere,
the acetylene oxygen flame cannot be used inside of pipes or structures subjected to
oxygen depletion from gas welding. By varying the relative amounts of acetylene and
oxygen, a welder can produce different flame atmospheres and temperatures as he
requires.
Oxy Fuel welding Gases
Commercial fuel gases have one common property: they all require oxygen to support
combustion. To be suitable for welding operations, a fuel gas, when burned with oxygen,
must have the following:
a. High flame temperature
b. High rate of flame propagation
c. Adequate heat content
d. Minimum chemical reaction of the flame with base and filler metals
Among the commercially available fuel gases such as propane, liquefied petroleum gas
(LPG), natural gas, propylene, hydrogen and MAPP gas, “Acetylene” most closely
meets all the above requirements.
Acetylene is a hydrocarbon, just as are propane, methane, and virtually all the
components which make up gasoline and fuel oils. However, it differs from those
hydrocarbons in a way that its molecule is made up of two carbon atoms and two
hydrogen atoms, the carbon atoms are joined by what chemists call a ”triple bond”.
When acetylene reaches its kindling* temperature; the bond breaks and releases
energy. In other hydrocarbons, the breaking of the bonds between the carbon atoms
absorbs energy. The triple bond is the reason that when acetylene and oxygen are
mixed and ignited, the flame can reach the temperature of 5700°F to 6300 °F, highest
among commonly used gaseous fuels.
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The other property of acetylene which you must remember is that acetylene/air mixtures
can be ignited when they contain anywhere from 2.5 percent acetylene to 80 percent
acetylene. Mixtures of methane (the principal component of natural gas) and air are
flammable when they contain as little as 5% methane and not more than 15% methane.
*Kindling Temperature – Kindling temperature is the lowest temperature at which a
substance bursts into flame.
The other two gases suitable for welding and cutting are:
a) MAPP
b) Hydrogen
MAPP gas is a registered product of the Dow Chemical Company. It is liquefied

petroleum gas mixed with methylacetylene-propadiene (acetylene + propane). It has the
storage and shipping characteristics of LPG and has a heat value a little less than
acetylene. Because it can be shipped in small containers for sale at retail stores, it is
used by hobbyist. MAPP gas can be used at much higher pressures than acetylene,
sometimes up to 40 or 50 psi in high-volume oxy-fuel cutting torches which can cut up to
12 inch thick steel. A MAPP gas leak is easy to identify because of its particularly terrible
odor.
Hydrogen produces low-temperature flame and is best for aluminum. Hydrogen flame is
non-luminous, commonly used for underwater welding (can be used at higher pressure
than acetylene).
Gasses suitable for cutting but NOT welding:
a) Propane
b) Methane
c) LPG
Hydrocarbon gases, such as propane, butane, city gas, and natural gas, are NOT
suitable for welding ferrous materials due to their oxidizing characteristics. Although
propane has a very high number of BTUs per cubic feet in its outer cone, it does not
burn as hot as acetylene in its inner cone and therefore not very useful for welding
operations. However with a right torch (injector style), propane can make a faster and
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cleaner cutting and is much more useful for heating and bending applications than
acetylene. In some instances, many nonferrous and ferrous metals can be braze welded
with care taken in the adjustment of flare and the use of flux.
Characteristics of Acetylene:
1) Hydrocarbon - It burns in two stages with primary combustion zone (cone flame)
and secondary combustion zone (envelope flame);
2) Acetylene is a colorless gas with a very distinctive, nauseating odor that is highly
combustible when mixed with oxygen.
3) Acetylene gas is formed by the mixture calcium carbide and water and is
composed of carbon and hydrogen having the chemical formula C2H2.
4) Neutral flame temperature of 5420°F at the end of the inner cone. This can be
increased to a maximum of about 5800°F by increasing the oxygen quantity
through the torch (oxidizing flame);
5) Combustible intensity is 12700 BTU/sec. /sq. ft. of cone area in a one to one
mixture of acetylene and oxygen through the torch;
6) Net heat value of 1433 BTU per cubic foot;
Advantages of Oxyacetylene Process
1) Does not require electricity;
2) The equipment is portable, easy to transport;
3) Welder has considerable control over the rate of heat input, the temperature of
the weld zone, and the oxidizing or reducing potential of the welding atmosphere;
4) Oxyacetylene process is ideally suited to the welding of thin sheet, tubes, and
small diameter pipe. It is also used for repair work, maintenance and in body
shops;
5) Dissimilar metals can easily be joined;
6) Can also be used for preheating, cutting metal, case hardening, soldering and
annealing.
Limitations of Acetylene
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1) Acetylene becomes extremely dangerous if used above 15 pounds pressure.

Pure acetylene is self-explosive if stored in the free state under a pressure of
29.4 pounds per square inch (psi);
2) The process is typically slower than the electrical arc-welding processes;
We will learn more about the oxyacetylene process and equipment in this course. The
course is divided into 4 sections:
Section -1 Oxy-Acetylene Apparatus
Section -2 Oxy-Acetylene Welding
Section -3 Oxy-Acetylene Cutting
Section -4 Oxy-Acetylene Safety & Precautions including case study
Annexure -1 Terminology
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SECTION - 1 OXY-ACETYLENE APPARATUS
Before discussing how the system works, it is important to know the name of the
components that makes the oxy-fuel apparatus.
Oxy-fuel apparatus consists of two cylinders (one oxygen and one acetylene) equipped
with two regulators, pressure gauges, two lengths of hose, and a blow torch. The
regulators are attached to cylinders and are used to reduce and maintain a uniform
pressure of gases at the torch. The gases at reduced pressure are conveyed to the torch
by the hoses. The regulators include high pressure and low pressure gauges to indicate
the contents of the cylinder and the working-pressure on each hose. When the gases
reach the torch they are there mixed and combustion takes place at the welding tip fitted
to the torch.
Oxy-acetylene welding outfit
The basic equipments used to carry out gas welding are:
1. Oxygen gas cylinder (green)
2. Acetylene gas cylinder (maroon/red)
3. Oxygen pressure regulator
4. Acetylene pressure regulator
5. Oxygen gas hose(Blue)
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6. Acetylene gas hose(Red)
7. Welding torch or blow pipe with a set of nozzles and gas lighter
8. Trolleys for the transportation of oxygen and acetylene cylinders
9. Set of keys and spanners
10. Filler rods and fluxes
11. Protective clothing for the welder (e.g., asbestos apron, gloves, goggles, etc.)
OXYGEN GAS CYLINDER
Oxygen cylinder is drawn from a piece of high strength steel plate and is available in
common sizes of:
o 244 cu ft (for industrial plants);
o 122 cu ft;
o 80 cu ft
Oxygen is stored within cylinders at a pressure of 2200 psi when filled @70°F and is
capable of retaining a pressure of almost twice the fill pressure.
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The oxygen volume in a cylinder is directly proportional to its pressure. In other words, if
the original pressure of a full oxygen cylinder drops by 10% during welding, it means
1/10th of the cylinder contents have been consumed.
Oxygen cylinders are usually painted green and are screwed right handed.
Oxygen Cylinder Valves
The oxygen cylinder valve is made largely of brass with right hand threads. Its outlet is
threaded and machined to comply with standards set by the Compressed Gas
Association (CGA) and the American National Standards Institute (ANSI). All oxygen
regulators sold in the U.S and Canada for use on industrial oxygen cylinders carry a
mating inlet nut and nipple. The connection is designated “CGA 540”. Every oxygen
cylinder valve is also equipped with a bursting disk which will rupture and release the
contents of the cylinder if cylinder pressure should approach cylinder test pressure (as it
might in case of a fire). In order to protect cylinder valve from getting damaged, a
removable steel cap is screwed on the cylinder at all times when the cylinder is not in
use. The cylinder valve is kept closed when the cylinder is not in use and even when
cylinder is empty.
Caution
o The valve shall never be left exposed. It must always have the regulator attached
or the cap on.
o The valve must be opened all the way when in use.
ACETYLENE GAS CYLINDER
An acetylene cylinder is also a solid drawn steel cylinder and the common sizes are 300,
120 and 75 cubic feet. Cylinder pressure is 250 PSI when filled. An acetylene cylinder is
painted maroon and the valves are screwed left handed (with grooved hex on nut or
shank).
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Acetylene is extremely unstable in its pure form at pressure above 15 PSI. This
instability places special requirements on the storage of acetylene. Acetylene cylinders
are packed with porous material (balsa wood, charcoal, corn pith, or portland cement)
that is saturated with acetone to allow the safe storage of acetylene. These porous filler
materials aid in the prevention of high-pressure gas pockets forming in the cylinder.
Acetone, a colorless, flammable liquid, is than added to the cylinder until about 40
percent of the porous material is saturated. Acetone is a liquid chemical that dissolves
large portions of acetylene under pressure without changing the nature of the gas and is
a liquid capable of absorbing 25 times its own volume of acetylene gas at normal
pressure. Being a liquid, acetone can be drawn from an acetylene cylinder when it is not
upright.
Here are two very important things to remember about dissolved acetylene
cylinders:
First, acetylene cylinders should always be stored in the upright position to prevent the
acetone form escaping thus causing the acetylene to become unstable.
Second, CGA G-1 calls for a withdrawal rate “not to exceed 1/10(one-tenth) of the
capacity of the cylinder per hour during intermittent use. For full withdrawal of the
contents of the cylinder on a continuous basis, the flow rate should be no more than 1/15
(one-fifteenth) of the capacity of the cylinder per hour.” If acetylene is withdrawn too
rapidly, quite a lot of acetone may come with it, in vapor or droplet form, and the cylinder
may cool down so much that it cannot sustain the high rate. This will affect your torch
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flame, and will mean that your supplier must replenish the acetone in the cylinder more
frequently.
Many acetylene cylinder valves are not equipped with hand wheels, and must be
operated by a wrench. The wrench should always be left in place while the cylinder valve
is open. Acetylene cylinders should be opened only 1/3 to ¼ of a turn when in use.
Pressure Relationship
In an oxygen cylinder there is a precise relationship between cylinder pressure and

cylinder contents. A standard oxygen cylinder that contains 244 cu-ft at 2200 psi @
700°F will contain 122 cu-ft when the pressure has dropped to 1100 psi at 700°F. In
contrast, an acetylene cylinder will not be precisely half-full when its pressure drops to
half. Note that the changes in temperature affect the pressure in an acetylene cylinder at
a much faster rate than it affects the pressure in an oxygen cylinder. Pressure in an
oxygen cylinder will go up or down only about 4 percent for each 20-degree change in
temperature (F) from 70 deg. A full acetylene cylinder which has a pressure of 250 psi
at 700°F will have a pressure of 315 psi at 900°F and a pressure of 190 psi at 500°F.
You must always take temperature into account when estimating how much acetylene
the cylinder contains.
Safety Devices on Acetylene Cylinder
An acetylene cylinder is protected by number of fusible plugs, which melt at 220°F

(104°C). These plugs melt and release the pressure in case the cylinder is exposed to
excessive heat. Small cylinders (the 10 cu-ft. and 40 cu-ft. sizes) have one fusible metal
channel located in the cylinder valve. The large cylinders normally used in welding and
cutting, with capacities ranging up to nearly 300 cubic feet of acetylene, have two to four
plugs, located in both top and bottom of the cylinders. If a cylinder is exposed to a fire,
one or more safety devices will melt and allow the acetylene and acetone to escape and
burn gradually. If it did not have such a safety device, a full acetylene cylinder exposed
to a fire would rupture and release its contents all at once, perhaps explosively.
Note: Acetylene cylinders are equipped with fusible metal safety plugs and NOT rupture-
disk safety devices, as in oxygen and nitrogen gas cylinders.
Caution
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o DO NOT adjust, alter, change, build, or do any experimental work on cylinders,

regulators, torches, or any other gas equipment;
o DO NOT lift cylinders by the caps or valves;
o DO NOT transport the cylinders without the caps in place;
o Cylinders must be stored in upright position;
o KEEP valves closed on empty cylinders;
o MAKE sure, cylinders are regularly re-tested using hydrostatic (NDE) while in
service.
Cylinder Transportation
o NEVER transport cylinders without the safety caps in place. When using fuel and
oxygen tanks they should be fastened securely upright to a post or a portable
cart. An oxygen tank is especially dangerous for the reason that the oxygen is at
a pressure of 3000 PSI when full and if the tank falls over and its valve strikes
something and is knocked off, the tank will effectively become an extremely
deadly flying missile propelled by the compressed oxygen;
o NEVER transport with the regulators in place;
o NEVER allow bottles to stand freely. Always chain them to a secure cart or some
other object that cannot be toppled easily.
Manifold System for Gas Welding
While a great deal of oxy-acetylene welding and cutting is done using gases supplied by
a single pair of cylinders, there are many situations where considerable gas welding is
done and at several places or where rate of gas consumption is high, it is much
advantageous to use a manifold system.
In a manifold system, instead of having gas cylinders at each place of work, they are
assembled at one centralized position in specially designed racks and connected by a
manifold. The gas is then distributed by means of a pipeline to different workplaces.
The manifold distributes welding gases at a reduced pressure. There are separate
manifolds for oxygen and acetylene gas supplies. An oxygen manifold system differs
from acetylene manifold in the following ways:
1. There is no anti flashback device in an oxygen manifold system.
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2. Oxygen supply line is a copper pipe whereas acetylene supply line is a steel
pipe.
3. An oxygen pressure regulator is used in an oxygen manifold system.
Advantages of Using Manifolds –
Since gas cylinders have not been scattered throughout the work area, rather, they have
been kept at a central place:
a) The possibility of accidents is reduced.
More space is available at each workplace.
In case of fire, one can easily reach the cylinders.
b) Cylinders are transported by less distance.
c) There is no replacement of cylinders inside the workshop.
OXYGEN & ACETYLENE PRESSURE REGULATORS
The pressure of the gases obtained from cylinders is considerably higher than the gas
pressure used to operate the welding torch. The purpose of using a gas pressure
regulator is:
• To reduce the high pressure of the gas in the cylinder to a suitable working
pressure, and
• To produce a steady flow of gas under varying cylinder pressures.
A pressure regulator is connected between the cylinder/generator and the hose leading
to welding torch. Desired pressure at the welding torch may be somewhere up to 35 psig
for oxygen and 15 psig for acetylene.
Cylinder Cylinder (Max on the Working (Max on the

pressure gauge) pressure gauge)
Oxygen 2200 psi (4000 psi) 1 to 35 psi (150 psi)
Acetylene 250 psi (400 psi) 1 to 12 psi (30 psi)
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A pressure regulator is fitted with two pressure gauges. One indicates the gas pressure
in the cylinder and the other shows the reduced pressure at which the gas is going out.
Gas pressure regulators may be classified as:
a) Single stage Regulator
b) Two stage Regulator
In single stage regulator, reduction of pressure from the cylinder pressure to the welding
pressures takes place in single stage. A single stage regulator is all that actually is
needed for both oxygen regulation and acetylene regulation for oxyacetylene welding.
However, a single stage regulator tends to freeze in cold weather. This is because a
sudden expansion and resulting drop in initial pressure causes rapid cooling of the gas
involved. The moisture present in the gas, thus, results in the formation of ice on or near
the regulator nozzle which causes irregular seating of the seat on the nozzle and
therefore substantial pressure fluctuations.
The principle of pressure reduction in a two stage regulator is exactly the same as in a
single stage regulator, but here the pressure is reduced in two stages instead of one,
using two diaphragms and two control valves, so that the pressure reduction ratio is less
abrupt.
Good regulators are essential to ensure the even flow of gas to the blowpipe. Acetylene
regulators are constructed much more sensitively than the oxygen regulators, to take
care of the lower pressure of gas. Acetylene regulators cannot be interchanged with
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oxygen regulators for they will not stand the pressure demanded in the first place, and in
the second if a small quantity of acetylene gas left in the regulator and oxygen
introduced, an inflammable mixture would be formed which is not advisable on account
of its explosiveness. In many instances oxygen regulators are put out with the copper
diaphragms, whereas another metal must be used on the acetylene regulators, because
acetylene gas attacks copper and usually a German silver or rubber diaphragm is used.
On account of the lower pressures used in charging the acetylene cylinders, lower
pressure gauges are used with acetylene regulators.
Difference between Oxygen and Acetylene Pressure Regulators -
Acetylene Regulator: The cylinder and hose connections have left handed threads on
the acetylene regulator.
Oxygen Regulator: There are right hand threads in this case.
Acetylene Regulator: Acetylene connection nuts have chamfers or grooves cut in them.
Oxygen Regulator: Nuts are plain, i.e., with no chamfer or grooves.
Acetylene Regulator: Color band on acetylene regulator in maroon or red.
Oxygen Regulator: It is either blue or black on the oxygen regulator.
Acetylene Regulator: The inlet or high pressure gauge on the regulator reads up to 8bar.
Oxygen Regulator: The inlet or high pressure gauge on the regulator reads up to 100bar.
Acetylene Regulator: The outlet or low pressure gauge on the regulator reads up to
1bar.
Oxygen Regulator: The outlet or low pressure gauge on the regulator reads up to 4.8bar.
Caution
o NEVER use oxygen or fuel gas from a cylinder except through an approved
pressure-reducing regulator.
o NEVER attempt to use a regulator except for the gas and service for which it is
designed. Generally speaking, the inlet connections installed by the regulator
manufacturer make mismatching impossible. However, that cannot always be the
case, since there just are not enough mechanically distinct connections to permit
each gas to have individual treatment. Therefore, some gases – for example, the
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inert gases and certain fuel gases – are treated in groups. A propane regulator
will fit many acetylene cylinders, but should not be so used.
o Oil or other petroleum products must never be used around oxygen regulators
because these products will either cause a regulator explosion or fire.
GAS HOSES & CLAMPS:
The hoses used to make the connections between the torch and the regulators must be
strong, nonporous, light, and flexible enough to make torch movements easy. The most
common type of cutting and welding hose is the twin or double hose that consists of the
fuel hose and the oxygen hose joined together side by side.
Size is determined by the inside diameter, and the proper size to use depends on the
type of work for which it is intended. Hose used for light work has a 3/1 6 or 1/4 inch
inside diameter and one or two plies of fabric. For heavy-duty welding and cutting
operations, use a hose with an inside diameter of 5/1 6 inch and three to five plies of
fabric. Single hose is available in the standard sizes as well as 1/2-, 3/4-, and 1-inch
sizes. These larger sizes are for heavy-duty heating and for use on large cutting
machines.
Rubber flexible hose
Oxygen hoses are green in color and have right hand thread. Acetylene hoses are red
in color with left hand thread. The nut on the acetylene connection has a notch that runs
around the center, distinguishing it from the nut on the oxygen connection. This is a
safety precaution to prevent hoses from being hooked up the wrong way.
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Some precautions are to be taken when using reinforced rubber hoses:
a) Only one gas should be used in a hose. For example, using an oxygen hose to
carry acetylene could cause a serious accident.
b) The hose should never be patched or repaired.
c) Hot metal (job) should never be placed on the hose.
The length of hose you use is important. The delivery pressure at the torch varies with
the length of the hose. A 20-foot, 3/16-inch hose maybe adequate for a job, but if the
same hose was 50 feet long, the pressure drop would result in insufficient gas flow to the
torch. Longer hoses require larger inside diameters to ensure the correct flow of gas to
the torch. When you are having problems welding or cutting, this is one area to check
Hose Clamps:
A metal clamp is used to attach the welding hose to a nipple. There are basically two
types of connections that can be used. The first is using a jubilee clip. The second option
is using a crimped connector. The second option is probably safer as it is harder for this
type of connection to come loose. The hoses should also be clipped together at intervals
approximately 3 feet apart.
Check Valve
A check valve lets gas flow in one direction only and is positioned at the torch inlet, and
at the regulator outlet. The purpose of check valve is to prevent flame or oxygen-fuel
mixture being pushed back into cylinder and causing backfire, flashback and explosion.
Backfire: A backfire is caused by the flame going out suddenly on the torch. A backfire
may occur when:
o The tip is touched against the work piece;
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o If the flame setting is too low;
o If the tip is dirty, damage or loose, or;
o If the tip is overheated.
When a torch backfires, it could cause a flashback.
A flashback is a condition in which the flame burns inside the tip, the torch, or the hose.
Flashbacks are caused by the improper mixture of the gases, which increases the rate of
flame propagation to such an extent that the flame will flash back to the mixing chamber.
If it is not stopped, the flame will ignite the mixture and will travel backwards from the
torch, along the hoses, through the regulator and into the cylinder. To prevent such
occurrence, a flash arrestor shall be installed. Flashback arrestor (not to be confused
with a check valve) prevents the shock waves from downstream coming back up the
hoses and entering the cylinder (possibly rupturing it), as there are quantities of
fuel/oxygen mixtures inside parts of the equipment (specifically within the mixer and
blowpipe/nozzle) that may explode, if the equipment is incorrectly shut down; and
acetylene decomposes at excessive pressures or temperatures. The flashback arrestor
will remain switched off until someone resets it.
(Refer to Section -4 “Safe Working Practices” illustrating a case study of safety incident
in UK.)
Note - Combination Check/ Flashback Valves can be placed at the torch or regulator.
WELDING TORCH & BLOW PIPE
A welding torch mixes oxygen and acetylene in the desired proportions, burns the
mixture at the end of the tip, and provides a means for moving and directing the flame.
There are two types of welding torches, namely:
a) High pressure (or equal pressure) type
b) Low pressure (or injector) type
High pressure blowpipes or torches are used with (dissolved) acetylene stored in
cylinders at a pressure of 117 psi. Low pressure blowpipes are used with acetylene
obtained from an acetylene generator at a pressure of 8 inch - head of water
(approximately 0.3 psi).
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In high pressure blow torch, both the oxygen and acetylene are fed at equal pressures
and the gases are mixed in a mixing chamber prior to being fed to the nozzle tip. The
high pressure torch also called the equal pressure torch is most commonly used
because:
a) It is lighter and simpler;
b) It does not need an injector;
c) In operation, it is less troublesome since it does not suffer from backfires to the
same extent.
To change the power of the welding torch, it is only necessary to change the nozzle tip
(size) and increase or decrease the gas pressures appropriately.
NOTE: The real tool of the oxy-acetylene welding process is the flame, NOT the torch.
When we come to oxygen cutting, we must consider the pure oxygen jet as a second
tool, working hand-in-hand with the flame. To produce only the flame, we use a welding
torch, fitted with the appropriate size welding head or tip. To produce both flames and
the oxygen jet, we use a cutting torch or cutting attachment, equipped with the
appropriate cutting nozzle or tip.
Welding Nozzles or Tips
The welding nozzle or tip is that portion of the torch which is located at the end of the
torch and contains the opening through which the oxygen and acetylene gas mixture
passes prior to ignition and combustion. Depending upon the design of the welding
torch, the interchangeable nozzles may consist of:
a) Either, a set of tips which screw onto the head of the blowpipe, or
b) As a set of gooseneck extensions fitting directly onto the mixer portion of the
blowpipe.
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A welding nozzle enables the welder to guide the flame and direct it with the maximum
ease and efficiency. The following factors are important in the selection of appropriate
welding nozzle:
a) The position of the weld
b) The type of joint
c) Job thickness and the size of welding flame required for the job
d) The metal/alloy to be welded.
To provide for different amounts of heat, to weld metals of different thicknesses, welding
tips are made in various sizes. The size of a welding tip is determined by the diameter of
the opening or orifice in the tip. As the orifice size increases, greater amounts of the
welding gases pass through and are burnt to supply a greater amount of heat.
The choice of the proper tip size is very important to good welding. For welding thicker
material large sized tip is used which will supply more combustible gases and more heat.
A chart giving sizes of tips for welding various thicknesses of metal along with oxygen
and acetylene pressures used is generally provided by the manufacturers.
Care of Welding tips
a) All welding tips are made of copper and may be damaged by careless handling.
b) Nozzles should never be dropped or used for moving or holding the work.
c) Nozzle seat and threads should be absolutely free from foreign matter in order to
prevent any scoring when tightening on assembly.
d) Nozzle orifice should only be cleaned with tip cleaners specially designed for this
purpose.
Filler Metals:
Filler metals are used to supply additional material to the pool to assist in filling the gap
(or groove) and it forms an integral part of the weld. Filler rods have the same or nearly
the same chemical composition as the base metal and are available in a variety of
compositions (for welding different materials) and sizes. These consumable filler rods
may be bare, or they may be coated with flux. The purpose of the flux is to retard
oxidation of the surfaces of the parts being welded, by generating gaseous shield around
the weld zone. The flux also helps to dissolve and remove oxides and other substances
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from the work piece and so contributes to the formation of a stronger joint. The slag
developed protects the molten metal puddles of metal against oxidation as it cools.
Characteristics of good flux
The melting point of a flux must be lower than that of either the metal or the oxides
formed, so that it will be liquid. The ideal flux has exactly the right fluidity when the
welding temperature has been reached. The flux will protect the molten metal from
atmospheric oxidation. Such a flux will remain close to the weld area instead of flowing
all over the base metal for some distance from the weld.
Composition of Fluxes
Fluxes differ in their composition according to the metals with which they are to be used.
In cast iron welding, a slag forms on the surface of the puddle. The flux serves to break
this up. Equal parts of a carbonate of soda and bicarbonate of soda make a good
compound for this purpose. Nonferrous metals usually require a flux. Copper also
requires a filler rod containing enough phosphorous to produce a metal free from oxides.
Borax which has been melted and powdered is often used as a flux with copper alloys. A
good flux is required with aluminum, because there is a tendency for the heavy slag
formed to mix with the melted aluminum and weaken the weld. For sheet aluminum
welding, it is customary to dissolve the flux in water and apply it to the rod. After welding
aluminum, all traces of the flux should be removed.
Gas Lighter
A gas (spark) lighter provides a convenient, safe and inexpensive means of lighting the
torch. Match sticks should never be used for this purpose because the puff of the flame
produced by the ignition of the acetylene flowing from the tip is likely to burn the welder's
hand. Spark lighters are constructed from flint and steel.
Gas Cylinder Trolleys
Trolleys should be capable of accommodating one oxygen cylinder and one acetylene
cylinder required for gas welding. Normally cylinders can be mounted on a trolley side by
side, but where work has to be done on plant with access only by narrow gangways the,
has an advantage. Trolleys may have rubber tires or steel rim wheels. The gas cylinders
are held in place with chains and supported on the bottom with a steel platform.
Goggles
15
They are used to protect the eyes of the operator from harmful heat and radiation of
infrared and ultraviolet rays produced during the welding.
Apron, Gloves & Safety Goggles
The molten metal has a tendency to pop and splatter as heat is applied and oxygen
reacts with the superheated metal. It is critical that operators using the oxy-acetylene
welding or cutting process wear proper gloves and use approved safety goggles or face
shield. The goggles and/or face shield protect the eyes from sparks and flying hot metal
particles. The goggles or face shield use special lenses to protect the eyes form light
damage. A variety of lenses are used depending on the type of welding or cutting that
needs to be done, the type of material, and the thickness of the material. If protective
eye shielding is not used, painful burns can occur on the surface of the eye, and could
result in permanent damage.
16
SECTION - 2 OXY- ACETYLENE WELDING
The oxyacetylene welding process uses a combination of oxygen and acetylene gas to
provide a high temperature flame. The high temperature flame melts the metal faces of
the work-pieces to be joined, causing them to flow together. A filler metal alloy is
normally added and sometimes used to prevent oxidation and to facilitate the metal
union.
The amount of heat applied to the metal is a function of the welding tip size, the speed of
travel, and the welding position. The flame size is determined by the welding tip size and
the proper tip size is determined by the metal thickness and the joint design.
Characteristics of the oxy-acetylene welding process include:
o The use dual oxygen and acetylene gases stored under pressure in steel
cylinders;
o Its ability to switch quickly to a cutting process, by changing the welding tip to a
cutting tip;
o The high temperature the gas mixture attains (~5800°F);
o The use of regulators to control gas flow and reduce pressure on both the
oxygen and acetylene tanks;
o The use of double line rubber hoses to conduct the gas from the tanks to the
torch;
o Melting the materials to be welded together;
o The ability to regulate temperature by adjusting gas flow.
Types of Welding Flames
In oxyacetylene welding, flame is the most important tool. All the welding equipment
simply serves to maintain and control the flame. The flame must be of the proper size,
shape and condition in order to operate with maximum efficiency. Three distinct types of
flames are possible on adjusting the proportions of acetylene and oxygen:
1. Neutral Flame (Acetylene oxygen in equal proportions)
2. Oxidizing Flame (Excess of oxygen)
3. Reducing Flame (Excess of acetylene)
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Neutral Flame
A neutral flame is produced when the ratio of oxygen to acetylene, in the mixture leaving
the torch, is almost exactly one-to-one. The temperature of the neutral flame is of the
order of about 5900ºF.
Neutral Flame (5850°F).

For Fusion welding of steel and cast iron
Characteristics of Neutral flame:
a) The neutral flame is obtained when approximately one volume of oxygen and
one volume of acetylene are mixed. It’s termed “neutral” because it will usually
have no chemical effect on the metal being welded. It will not oxidize the weld
metal; it will not cause an increase in the carbon content of the weld metal.
b) Neutral flame is obtained by gradually opening the oxygen valve to shorten the
acetylene flame until a clearly defined inner cone is visible. For a strictly neutral
flame, no whitish streamers or feathers should be present at the end of the cone.
c) Neutral flame is used for most welding operations and for preheating during
cutting operations. When welding steel with neutral flame, the molten metal
puddle is quiet and clear; the metal flows easily without boiling, foaming, or
sparking.
d) There are two clearly defined zones in the neutral flame. The inner zone consists
of a luminous cone that is bluish-white. The inner cone is where the acetylene
and the oxygen combine. Surrounding this is a light blue flame envelope or
sheath. This neutral flame is obtained by starting with an excess acetylene flame
in which there is a "feather" extension of the inner cone. When the flow of
acetylene is decreased or the flow of oxygen increased the feather will tend to
disappear. The neutral flame begins when the feather disappears.
18
e) The tip of the inner is the hottest part of the flame and is approximately 5850ºF,
while at the end of the outer sheath or envelope the temperature drops to
approximately 2300ºF. This variation within the flame permits some temperature
control when making a weld. The position of the flame to the molten puddle can
be changed, and the heat controlled in this manner.
f) The neutral flame is commonly used for the welding of:
o Mild steel
o Stainless steel
o Cast Iron
o Copper
o Aluminum
Carburizing or Reducing Flame:
If the volume of oxygen supplied to the neutral flame is reduced, the resulting flame will
be a carburizing or reducing flame, i.e. rich in acetylene. A reducing flame can be
recognized by acetylene feather which exists between the inner cone and the outer
envelope. The outer flame envelope is longer than that of the neutral flame and is
usually much brighter in color.
Carburizing Flame (Excess acetylene with oxygen, 5700°F)
Used for hard facing and welding white metal.
Characteristics of Reducing or carburizing flame:
19
a) An excess of acetylene creates a carburizing flame. The reducing or carburizing

flame is obtained when slightly less than one volume of oxygen is mixed with one
volume of acetylene. This flame is obtained by first adjusting to neutral and then
slowly opening the acetylene valve until an acetylene streamer or "feather" is at
the end of the inner cone. The length of this excess streamer indicates the
degree of flame carburization. For most welding operations, this streamer should
be no more than half the length of the inner cone.
b) The carburizing flame is characterized by three flame zones; the hot inner cone,
a white-hot "acetylene feather", and the blue-colored outer cone. This is the type
of flame observed when oxygen is first added to the burning acetylene. The
feather is adjusted and made ever smaller by adding increasing amounts of
oxygen to the flame. A welding feather is measured as 2X or 3X, with X being the
length of the inner flame cone. This type of flare burns with a coarse rushing
sound. It has a temperature of approximately 5700ºF (3149ºC) at the inner cone
tips.
The feather is caused by incomplete combustion of the acetylene to cause an excess

of carbon in the flame.
c) The carburizing flame may add carbon to the weld metal and will tend to remove
the oxygen from iron oxides which may be present, a fact which has caused the
flame to be known as a “reducing flame”. With iron and steel it produces very
hard, brittle substance known as iron carbide. This chemical change makes the
metal unfit for many applications in which the weld may need to be bent or
stretched. Metals that tend to absorb carbon should NOT be welded with
reducing flame.
d) The reducing flame is typically used for welding high carbon steel and hard
facing operations or backhand pipe welding techniques. When used in silver
solder and soft solder operations, only the intermediate and outer flame cones
20
are used. They impart a low temperature soaking heat to the parts being
soldered.
e) Since this flame provides a strong reducing atmosphere in the welding zone, it is
useful for those materials which are readily oxidized like oxygen free copper
alloys. It is also used for high carbon steels, cast iron and hard surfacing with
high speed steel and cement carbides. A reducing flame has an approximate
temperature of 5500°F (which is lowest among all the three flames). A reducing
flame may be distinguished from a carburizing flame by the fact that a carburizing
flame contains more acetylene than a reducing flame. A carburizing flame is
used in the welding of lead and for carburizing (surface hardening) purposes. A
reducing flame, on the other hand, does not carburize the metal; rather it ensures
the absence of the oxidizing condition. It is used for welding with low alloy steel
rods and for welding those metals, (e.g. non ferrous) that do not tend to absorb
carbon. This flame is very well used for welding high carbon steel.
Oxidizing Flame:
The oxidizing flame is the third possible flame adjustment. It occurs when the ratio of
oxygen to acetylene required for a neutral flame is changed to give an excess of oxygen.
This flame type is observed when welders add more oxygen to the neutral flame.
Oxidizing Flame (Acetylene and excess oxygen, 6300°F)
For braze welding with Bronze rod.
The presence of excess oxygen in this flame creates undesirable oxides to the structural
and mechanical detriment of most metals. It is useful for welding copper base alloys,
zinc base alloys, cast iron, manganese steel etc.
Characteristics of an Oxidizing flame:
a) The oxidizing flame is produced when slightly more than one volume of oxygen is
mixed with one volume of acetylene. To obtain this type of flame, the torch
should first be adjusted to a neutral flame. The flow of oxygen is then increased
21
until the inner cone is shortened to about one-tenth of its original length. When
the flame is properly adjusted, the inner cone is pointed and slightly purple. An
oxidizing flame can also be recognized by its distinct hissing sound. The
temperature of this flame is approximately 6300ºF (3482ºC) at the inner cone tip.
b) An oxidizing flame can be recognized by the small white cone which is shorter,
much bluer in color and more pointed than that of the neutral flame. The outer
flame envelope is much shorter and tends to fan out at the end on the other hand
the neutral and carburizing envelopes tend to come to a sharp point.
c) An oxidizing flame burns with a decided loud roar. An oxidizing flame tends to be
hotter than the other two flames. This is because of excess oxygen which causes
the temperature to rise as high as 6300°F and not heat up as much thermally
inert carbon.
d) When applied to steel, an oxidizing flame especially at high temperatures tends

to combine with many metals to form hard, brittle, low strength oxides. This
indicates that the excess oxygen is combining with the steel and burning it.
Moreover, an excess of oxygen causes the weld bead and the surrounding area
to have a scummy or dirty appearance. This flame will ruin most metals and
should be avoided, except as noted below.
e) An oxidizing flame is of limited use in welding. It is not used in the welding of

steel. A slightly oxidizing flame is helpful when welding most
o Copper base metals
o Zinc base metals, and
o A few types of ferrous metals, such as manganese steel and cast iron
A stronger oxidizing flame is used in the welding of brass or bronze. The oxidizing
atmosphere, in these cases, creates a base metal oxide that protects the base metal.
For example, in welding brass, the zinc has a tendency to separate and fume away. The
formation of a covering copper oxide prevents the zinc from dissipating.
To conclude, for most welding operations the Neutral Flame is correct, but the other
types of flames are sometimes needed for special welds, e.g., non-ferrous alloys and
high carbon steels may require a reducing flame, whilst zinc bearing alloys may need an
oxidizing flame for welding purposes.
22
SETTING UP AN OXYACETYLENE TORCH
Before you begin a welding operation, make a thorough inspection of the area. Ensure
that there are no combustible materials in the area that could be ignited by the sparks or
slag produced by the welding operation.
Safety check
1) Read carefully the safety considerations;
2) Oxygen and acetylene cylinders must be securely stored in an upright position;
3) An oxyacetylene torch can produce a large amount of heat. Be aware that any
objects you direct the flame towards will become hot;
4) Always have a suitable fire extinguisher near your work area;
5) Make sure that you understand and observe all legislative and personal safety
procedures when carrying out the following tasks. If you are unsure of what these
are, ask your supervisor.
Caution
1) If a cylinder falls over and breaks the main valve off, the cylinder will become a
missile and cause extreme damage.
2) Wear a leather apron or similar protective clothing and welding gloves when
using an oxyacetylene torch.
3) Always use proper welding goggles. Do not use sunglasses because they do not
filter the extreme ultraviolet light as effectively. The plastic used in sunglass
lenses will not protect your eyes from sparks. Use face mask and valved
respirators.
4) Never point the lighted flame toward another person or any flammable material.
5) Always light the oxyacetylene torch with the striker. A cigarette lighter or match
would put your hand too close to the igniting tip.
6) Wherever possible, use a heat shield behind the component you are heating.
This will prevent nearby objects from becoming hot.
23
7) After heating a piece of metal, label it as "HOT" with a piece of chalk so that
others will not attempt to pick it up.
Component identification
It is important to learn the names of all associated equipment and auxiliaries related to
oxy-acetylene process. Some parts of this illustration are labeled.
STEP – BY – STEP INSTRUCTION
Check equipment
24
First, make sure that the gas flow from both the oxygen and the acetylene cylinders is
turned off tightly. The two cylinders are secured in an upright position. This is usually on
a wheeled trolley. Look at the hose pressure and cylinder pressure gauges on top of
each cylinder. Both gauges on each cylinder should read zero. If both gauges do not
read zero, turn the main cylinder valve on the top of the cylinder clockwise, to close it
completely. Then you must purge the system of any gas.
Purge the system
It is recommended that you purge the gas lines before use to ensure that no oxygen is in
the acetylene line and vice versa. Ensure that you have adequate ventilation.
To purge the system, make sure the main cylinder valve is closed tightly. Pick up the
torch handle and note that it has two hoses attached. One hose supplies acetylene, the
other oxygen. Turn the oxygen regulator under the gauges clockwise, and open the
oxygen valve on the handle. This will purge any gas that may still be in the system and
the gauges should both drop back to zero. For a 20 foot hose, open the torch valve for 5
seconds to allow oxygen to bleed from the line acetylene line. For a longer hose, consult
a welding reference. Repeat this procedure with the acetylene cylinder.
Install the torch handle
The torch handle is the connection between the hoses and the working tips. It consists of
a body and two taps. It’s used for both welding and heating. Different attachments are
connected to the handle to enable welding, heating or cutting. Examine the connections.
One connection is marked”OX”, and is for the oxygen hose. The other is marked “AC”,
and is for the acetylene hose.
Connect the hoses
As a further safety precaution, you’ll find the oxygen connector is right hand thread and
the acetylene connector is a left hand thread.
Install the correct tip
Welding tips come in sizes that are stamped with a number. Number one is the smallest
tip. The relation between the tip number and the diameter of the orifice may vary with
different manufacturers. However, the smaller number always indicates the smaller
diameter. For the approximate relation between the tip number and the required oxygen
and acetylene pressures, see tables below.
25
Low Pressure or Injector Type Torch
Tip Size No. Oxygen, psi Acetylene, psi

0 9 1
1 9 1
2 10 1
3 10 1
4 11 1
5 12 1
6 14 1
7 16 1
8 19 1
10 21 1
12 25 1
15 30 1
Equal Pressure Type Torch
Tip Size No. Oxygen, psi Acetylene, psi

1 2 2
3 3 3
4 3 3
5 3.5 3.5
6 3.5 3.5
7 5 5
8 7 7
9 9 9
10 12 12
The choice of the tip size depends on the thickness of the metal to be joined. Larger
torch tip sizes cause higher amount of oxygen and fuel to flow out causing the release of
more heat.
Notes:
1. Tips are provided by a number of manufacturers, and sizes may vary slightly.
26
2. Oxygen pressures are approximately the same as acetylene pressures in the

balanced pressure type torch. Pressures for specific types of mixing heads and
tips are specified by the manufacturer.
Adjust the pressure of the gas flow
You are now ready to adjust the gas pressure for heating. Look at the two valves on the
torch handle. The valve next to the oxygen hose controls the flow of oxygen to the tip.
Close it tightly clockwise. The valve next to the acetylene hose controls the flow of
acetylene to the tip. Also, close it tightly clockwise.
Turn on the gases
Now that you’re ready to use the torch, turn the main valve on the top of each cylinder
counter-clockwise half a turn to open the valve. The oxygen tank valve is a backstop
valve and should be opened all the way in order to completely seal. The acetylene valve
should only be opened 1/4 to 1/3 of a turn. The needle on the cylinder pressure gauge
will rise to show you the pressure in the cylinder. Turn the oxygen regulator handle
clockwise until the needle in the gauge registers 10 psi. Turn the acetylene regulator
handle clockwise until the needle in the gauge registers 5 psi. This is your working
pressure for heating.
Make sure the valves are easily accessible in case emergency shutdown is necessary.
Check the area
Before you light the torch, check the area you’re working in to make sure there are no
flammable materials or fluids nearby. Workmates should also be clear of the area. The
welding flame is not only extremely hot; it also produces dangerous ultra violet rays,
which will damage your eyes. It is absolutely vital that you are wearing the right safety
gear: gloves and tinted goggles or face mask. So put them on and adjust them
comfortably.
Ignite the torch
Now you are ready to ignite the torch with the striker. The tip of the torch must be
pointing downwards away from your body and away from the gas cylinders.
1) Hold the striker against the tip of the torch with the lighter cup between the torch
and you. Flick the striker to create the spark while opening the acetylene valve
slightly (1/4 turn). This will ignite the gas at the tip of the torch.
27
2) Once the flame is lit, open the acetylene valve just until the flame stops smoking.
You should get a flame about 8 inches long with a toothy splintering end.
3) Now introduce oxygen into the flame by opening the oxygen valve on the torch.
4) Adjust the two valves (cutting torch oxygen and acetylene) until you obtain a
short, bright blue flame at the torch tip with no yellow.
5) Adjust the acetylene regulator to approximately 10 psi. Turn the screw in to

increase the pressure and out to decrease it.
6) Adjust the oxygen regulator in the same manner to a pressure between 40 and
60 psi.
7) Adjust the acetylene and oxygen valves as necessary to maintain the correct
flame. The actual adjustment of the flame depends on the type of material to be
joined.
Flame Adjustment for Oxy-acetylene Welding
Metal Flame
Mild Steel Neutral
High Carbon Steel Reducing
Grey Cast Iron Neutral, Slightly Oxidizing
Alloy Steel Neutral
Lead Neutral
Aluminum Slightly Carburizing
Brass Slightly Oxidizing
Copper, Bronze Neutral, Slightly Oxidizing
Nickel Alloy Slightly Carburizing
Caution
o Check all connections before lighting the torch.
o NEVER use a match or butane lighter to light the flame. Always use a flint and
steel spark lighter to light the oxygen acetylene flame.
o BEFORE LIGHTING TORCH, be positive that hose, tanks, or any inflammable

material will not be exposed to heat, flame, or sparks.
28
o Never stand directly in front of or behind a regulator when opening the cylinder
valve.
o Turn both cylinders off immediately when the torch flashes back or is burning on
the inside: first oxygen and then acetylene.
o Never open both fuel (acetylene) and oxygen valves before lighting the preheat
flame. ALWAYS turn the oxygen cylinder valve all the way open.
o Open the acetylene cylinder valve not more than one turn. One-half turn is
preferred.
Adjust the flame
As you open the oxygen valve, you will see the color of the flame change. The pure
acetylene flame is yellow, and it will change to blue as you add the oxygen. Continue to
open the oxygen valve until you can observe a small, sharp blue cone in the center of
the torch flame. This is the “neutral” flame you need for general heating.
The inner cone or vivid blue flare of the burning mixture of gases issuing from the tip is
called the working flare. The closer the end of the inner cone is to the surface of the
metal being heated or welded, the more effective is the heat transfer from flame to
metal. The flame can be made soft or harsh by varying the gas flow. Too low a gas flow
for a given tip size will result in a soft, ineffective flame sensitive to backfiring. Too high a
gas flow will result in a harsh, high velocity flame that is hard to handle and will blow the
molten metal from the puddle.
The chemical action of the flame on a molten pool of metal can be altered by changing
the ratio of the volume of oxygen to acetylene issuing from the tip. Most oxyacetylene
welding is done with a neutral flame having approximately a 1:1 gas ratio. An
oxidizing action can be obtained by increasing the oxygen flow, and a reducing action
will result from increasing the acetylene flow. Both adjustments are valuable aids in
welding.
Using the Torch
The torch tip should be positioned above the metal plate so that the white cone is at a
distance of 1.5 to 3.0 mm from the plate. The torch should be held at an angle of 45 to
60° from the horizontal plane.
29
The torch movement along the joint should be either oscillating or circular. In forehand
welding, the torch is moved in the direction of the tip. This tends to preheat before the
white cone of the tip melts it. In backhand welding the torch moves backwards. The
outer blue flames are directed on the already welded joint. This allows the joint to be
continuously annealed relieving the welding stresses. This welding allows a better
penetration as well as form bigger weld. Backhand welding is generally used for thicker
materials.
When the welding rod is used to provide filler material, it is necessary to hold it at a
distance of 10 mm from the flame and 1.5 to 3.0 mm from the surface of the weld metal
pool or puddle. This way the rod gets preheated and when dipped into the puddle would
readily get melted.
Oxy-fuel welding can be used for all the types of joints in all positions. Overhead usage
requires additional skill to safeguard the welder. The various butt joint edge preparations
are shown in the adjacent figure.
30
Thicker plates require more than one pass of the gas torch along the length to complete
the joint. In multi pass welding, the first pass (root pass) is very critical in any welding
operation.
Weld Appearances
Welding gas pressures are set in accordance with the manufacturer's recommendations.
The welder will modify the speed of welding travel to maintain a uniform bead width.
Trained welders are taught to keep the bead the same size at the beginning of the weld
as at the end. If the bead gets too wide, the welder increases the speed of welding
travel. If the bead gets too narrow or if the weld puddle is lost, the welder slows down the
speed of travel. Welding in the vertical or overhead positions is typically slower than
welding in the flat or horizontal positions.
The welder must add the filler rod to the molten puddle. The welder must also keep the
filler metal in the hot outer flame zone when not adding it to the puddle to protect filler
metal from oxidation. Do not let the welding flame burn off the filler metal. The metal will
not wet into the base metal and will look like a series of cold dots on the base metal.
There is very little strength in a cold weld. When the filler metal is properly added to the
molten puddle, the resulting weld will be stronger than the original base metal.
31
Weld Appearances
To Extinguish the Flame and Stop Welding
1. When the welding or cutting operation is finished, close the torch acetylene valve
first and then turn off the torch oxygen valve.
2. Close the oxygen cylinder valve.
3. Release the pressure in the hose and regulator by opening the oxygen control
valve on the torch.
4. Release the pressure on the oxygen regulator diaphragm by turning the regulator
to the minimum pressure position.
5. Close the oxygen control valve on the torch.
6. Repeat the same procedure for purging acetylene.
Caution
o ALWAYS weld at least 5 feet from the cylinders
o ALWAYS place the welding tip so that it points to the side of the torch to which
the acetylene hose is attached
o DO NOT use any oil or grease on any oxygen or acetylene connections
o NEVER hammer on oxygen or acetylene regulators or stuck valves
o BEWARE OF HIGH ACETYLENE PRESSURE. NEVER USE ACETYLENE GAS

WHEN THE PRESSURE IS GREATER THAN 15 POUNDS PER SQ. IN.
(acetylene gas when compressed to more than 15 pounds per sq. in. become a
very high explosive.)
o DO NOT hold welding or cutting tip too close to your work
o NEVER LEAVE TORCH BURNING AND GO AWAY FROM IT
o NEVER leave torch valves open
Perfecting the Weld
There are several factors that impact on the quality of weld. These factors include:
o Tip size
o Rod size
32
o Flame size
o Preparation of metal
o Torch or rod angle
o Distance between torch and work
o Speed and method of torch movement
o Maintenance of equipment
Tip and rod size
You need to select the proper tip size for the job to get the correct heat for the metal
being welded. Some general guidelines include:
o Tips need to be selected to match the size of filler rod used and the thickness of
the gauge metal being welded. The larger the filler rod, the thicker the metal, the
higher the number of tip to be used.
o As a basic rule of thumb, choose a rod size that is the same thickness as the
metal that you are welding.
o Tip sizes 3, 5 and 7 are common sizes to use for steel between 1/16” and 1/8”
thick.
Flame Size
If the puddle is not moving properly, it may be because of incorrect tip size or it may
mean you need to adjust your torch valve setting slightly. Remember that you also need
to have the torch set for the correct flame type – usually neutral.
Preparation of Metal
Metal should be free of rust, grease, oil and paint. Use a grinder or wire brush to remove
rust or paint. Anything that has had oil or grease on it should be avoided as it is
potentially toxic and flammable when heated.
Torch or Rod Angle
The angle between the torch flame and the steel helps you to move the weld puddle
where you want it. Change the angle that you are working until you find the angle that
works best, usually 45 to 60 degrees.
Distance between torch and work
33
The close you hold the torch to your work, the more heat is created. The greater heat
increases the depth of penetration of the weld and makes the weld puddle narrower.
Speed and method of torch movement
Slower speed will make a wider weld with a deeper penetration. The object is to get a
flat weld. To achieve that you may need some slight back and forth or oval motions with
the torch. A steady, even speed and movement is important to achieving a quality weld.
Maintenance of equipment
If your tip becomes plugged, the flame will go sideways and splutter or go out. You need
to be sure that your tips are kept clean with a tip cleaner.
The tip wears, becomes blackened, and pitted as you work with it. The tip cleaning tools
has a flat file you can use to file the tip flat again. The cleaning tool has tip cleaners for
each size of the tip. Be sue to use the right size of cleaner for the tip you are cleaning as
you may damage it. Be very careful when using these cleaners as they can break off
inside the tip.
Advantages of Gas Welding –
1) Welder has considerable control over the rate of heat input, the temperature of
the weld zone, and the oxidizing or reducing potential of the welding atmosphere;
2) As the source of heat and filler metal are separated, the metal deposition can be
easily controlled and heat properly adjusted giving rise to a satisfactory weld;
3) Welding equipment is portable and can be operated at remote places. Besides

gas welding, the equipment can be used for preheating, post heating, braze
welding, torch brazing and it is readily converted to oxygen cutting;
4) Weld bead size and shape and weld puddle viscosity are also controlled in the
welding process because the filler metal is added independently of the welding
heat source;
5) Gas welding is ideally suited to the welding of thin sheet, tubes, and small
diameter pipe. It is also used for repair welding. Thick section welds, except for
repair work, are not economical.
Limitations of gas welding:
1) Gas flame takes a long time to heat up the metal than an arc;
34
2) Flame temperature is less than the temperature of the arc;
3) Slower speed of welding compared electric arc welding;
4) Heavy sections cannot be joined efficiently;
5) For heavy sections proper penetration may not be achieved;
6) Refractory metals (e.g., tungsten, molybdenum, tantalum, etc.) and reactive

metals (e.g., titanium and zirconium) cannot be gas welded;
7) Flux used in the filler metal provides fumes which are irritating to the eyes, nose,
throat and lungs;
8) More safety is recommended in gas welding;
9) Acetylene and oxygen are expensive gases;
10) Prolonged heating of the joint may results in large HAZ. This often leads to
increased grain growth, more distortion and, in some cases, loss of corrosion
resistance.
Applications of Gas Welding –
1) For joining of thin materials. The process is used extensively for soldering copper
tubing;
2) For joining materials in whose case excessively high temperatures or rapid

heating and cooling of the job would produce unwanted or harmful changes in
the metal;
3) For joining materials in whose case extremely high temperatures would cause
certain elements in the metal to escape into the atmosphere;
4) For joining most ferrous and nonferrous metals, e.g., carbon steels, alloy steels,
cast iron, aluminum, copper, nickel, magnesium and its alloys, etc;
5) In automotive and aircraft industries. In sheet metal fabricating plants, etc.
35
SECTION – 3 GAS CUTTING
The equipment and accessories for oxy-gas cutting are the same as for oxy-gas welding
except that you use a cutting torch or a cutting attachment instead of a welding torch.
The main difference between the cutting torch and the welding torch is that the cutting
torch has an additional tube for high-pressure oxygen, along with a cutting tip or nozzle.
The tip is provided with a center hole through which a jet of pure oxygen passes. Mixed
oxygen and acetylene pass through holes surrounding the center holes for the
preheating flames. The number of orifices for oxyacetylene flames ranges from 2 to 6,
depending on the purpose for which the tip is used. The cutting torch is controlled by a
trigger or lever operated valve. The cutting torch is furnished with interchangeable tips
for cutting steel from less than ¼” to more than 12.0” in thickness.
Cutting Torch
OPERATION OF CUTTING EQUIPMENT
Setting up the oxyacetylene equipment and preparing for cutting must be done carefully
and systematically to avoid costly mistakes. Refer below the Step-by-Step instructions
before any attempt is made to light the torch:
1) Secure the cylinders so they cannot be accidently knocked over. A good way to
do this is to either put them in a corner or next to a vertical column and then
36
secure them with a piece of line. After securing the cylinders, remove the
protective caps.
2) Standing to one side, crack each cylinder valve slightly and then immediately
close the valve again. This blows any dirt or other foreign matter out of the
cylinder valve nozzle. Do not bleed fuel gas into a confined area because it may
ignite. Ensure the valves are closed and wipe the connections with a clean cloth.
3) Connect the fuel-gas regulator to the fuel-gas cylinder and the oxygen regulator
to the oxygen cylinder. Using a gang wrench, snug the connection nuts
sufficiently to avoid leaks.
4) Back off the regulator screws to prevent damage to the regulators and gauges
and open the cylinder valves slowly. Open the fuel-gas valve only one-half turn
and the oxygen valve all the way. Some fuel-gas cylinders have a hand-wheel for
opening the fuel-gas valve while others require the use of a gang wrench or T-
handle wrench. Leave the wrench in place while the cylinder is in use so the fuel-
gas bottle can be turned off quickly in an emergency. Read the high-pressure
gauge to check the contents in each cylinder.
5) Connect the RED hose to the fuel-gas regulator and the GREEN hose to the
oxygen regulator. Notice the left-hand threads on the fuel-gas connection.
6) To blow out the oxygen hose, turn the regulator screw in (clockwise) and adjust
the pressure between 2 and 5 psig. After the hose has been purged, turn the
screw back out again (counterclockwise) to shutoff the oxygen. Do the same for
the fuel-gas hose, but do it ONLY in a well-ventilated place that is free from
sparks, flames, or other possible sources of ignition.
7) Connect the hoses to the torch. The RED (fuel-gas) hose is connected to the
connection gland with the needle valve marked “FUEL.” The GREEN (oxygen)
hose is connected to the connection gland with the needle valve marked “OXY.”
8) With the torch valves closed, turn both regulator screws clockwise to test the
hose connections for leaks. If none are found, turn the regulator screws
counterclockwise and drain the hose by opening the torch valves.
9) Select the correct cutting tip and install it in the cutting torch head. Tighten the
assembly by hand, and then tighten with your gang wrench.
37
10) Adjust the working pressures. The fuel-gas pressure is adjusted by opening the
torch needle valve and turning the fuel-gas regulator screw clockwise. Adjust the
regulator to the working pressure needed for the particular tip size, and then
close the torch needle valve. To adjust acetylene gas, you should set the gauge
pressure with the torch valves closed. To adjust the oxygen working pressure,
you should open the oxygen torch needle valve and proceed in the same manner
as in adjusting the fuel-gas pressure.
11) In lighting the torch and adjusting the flame, always follow the manufacturer’s
directions for the particular model of torch being used. This is necessary because
the procedure varies somewhat with different types of torches and, in some
cases, even with different models made by the same manufacturer. In general,
the procedure used for lighting a torch is to first open the torch oxygen needle
valve a small amount and the torch fuel-gas needle valve slightly more,
depending upon the type of torch. The mixture of oxygen and fuel gas coming
from the torch tip is then lighted by means of a spark igniter or stationary pilot
flame. Adjust the preheating flame to neutral.
12) Hold the torch so that the cutting oxygen lever or trigger can be operated with
one hand. Use the other hand to steady and maintain the position of the torch
head to the work. Keep the flame at a 90 degree angle to work in the direction of
travel. The inner cones of the preheating flames should be about 1/16 in. (1.6
mm) above the end of the line to be cut. Hold this position until the spot has been
raised to a bright red heat, and then slowly open the cutting oxygen valve.
13) Cutting is initiated by heating the edge or leading face (as in cutting shapes such
as round rod) of the steel to the ignition temperature (approximately bright red
heat) using the pre-heat jets only, then using the separate cutting oxygen valve
to release the oxygen from the central jet. The oxygen chemically combines with
the iron in the ferrous material to instantly oxidize the iron into molten iron oxide,
producing the cut. If the cut has been started properly, a shower of sparks will fall
from the opposite side of the work. Move the torch at a speed which will allow the
cut to continue penetrating the work. A good cut will be clean and narrow.
14) When cutting billets, round bars, or heavy sections, time and gas are saved if a
burr is raised with a chisel at the point where the cut is to start. This small portion
38
will heat quickly and cutting will start immediately. A welding rod can be used to
start a cut on heavy sections. When used, it is called a starting rod.
Caution
NEVER use matches to light the torch; their length requires bringing the hand too close
to the tip. Accumulated gas may envelop the hand and, upon igniting, result in a severe
burn. Also, never light the torch from hot metal.
CUTTING MILD-CARBON STEEL
To cut mild-carbon steel with the oxyacetylene cutting torch, you should adjust the
preheating flames to neutral. Hold the torch perpendicular to the work, with the inner
cones of the preheating flames about 1/16 inches above the end of the line to be cut
(refer figure below). Hold the torch in this position until the spot you are heating is a
bright red. Open the cutting oxygen valve slowly but steadily by pressing down on the
cutting valve lever.
When the cut is started correctly, a shower of sparks will fall from the opposite side of
the work, indicating that the flame has pierced the metal. Move the cutting torch forward
39
along the line just fast enough for the flame to continue to penetrate the work
completely. If you have made the cut properly, you will get a clean, narrow cut that looks
almost like it was made by a saw.
A good cut is characterized by very small or negligible drag. When the torch is moved
too rapidly, the metal at the bottom does not get sufficient heat to get oxidized and cut
and hence there is a large drag. When the torch is moved slowly, all the preheated metal
is burnt away by the oxygen jet and a large amount of slag is generated.
Drag Figure
*Kerf - The narrow slit formed in metal as cutting progresses. The ideal kerf is a narrow
gap with a sharp edge on either side of the work piece; overheating the work piece and
thus melting through it causes a rounded edge.
Cutting Thick Steel
Steel, that is greater than 1/8 inch thick, can be cut by holding the torch so the tip is
almost vertical to the surface of the metal. If you are right-handed, one method to cut
steel is to start at the edge of the plate and move from right to left. Left-handed people
tend to cut left to right. Both directions are correct and you may cut in the direction that is
most comfortable for you. Figure below shows the progress of a cut in thick steel.
40
Progress of a cut in thick steel
After heating the edge of the steel to a dull cherry red, open the oxygen jet all the way by
pressing on the cutting lever. As soon as the cutting action starts, move the torch tip at
an even rate. Avoid unsteady movement of the torch to prevent irregular cuts and
premature stopping of the cutting action.
To start a cut quicker in thick plate, you should start at the edge of the metal with the
torch angled in the opposite direction of travel. When the edge starts to cut, bring the
torch to a vertical position to complete the cut through the total thickness of the metal. As
soon as the cut is through the metal, start moving the torch in the direction of travel.
Two other methods for starting cuts are used. In the first method, you nick the edge of
the metal with a cold chisel at the point where the cut is to start. The sharp edges of the
metal upset by the chisel will preheat and oxidize rapidly under the cutting torch,
allowing you to start the cut without preheating the entire edge of the plate. In the
second method, you place an iron filler rod at the edge of a thick plate. As you apply the
preheat flames to the edge of the plate, the filler rod rapidly reaches the cherry red
temperature. At this point, turn the cutting oxygen on and the rod will oxidize and cause
the thicker plate to start oxidizing.
Cutting Thin Steel
Though the gas cutting is more useful with thick plates, thin sheets (1/8 inch or less) can
also be cut by this process taking special precautions. Tip size chosen should be as
small as possible. If small tips are not available, then the tip is inclined at an angle of 15
to 20 degrees and point the tip in the direction the torch is traveling. By tilting the tip, you
41
give the preheating flames a chance to heat the metal ahead of the oxygen jet, as shown
in figure below. If you hold the tip perpendicular to the surface, you decrease the amount
of preheated metal and the adjacent metal could cool the cut enough to prevent smooth
cutting action.
Torch position for cutting thin sheets
Common gauge settings for cutting
• 1/4” material - Oxygen: 30-35psi; Acetylene: 3-9 psi
• 1/2” material - Oxygen: 55-85psi; Acetylene: 6-12 psi
• 1” material - Oxygen: 110-160psi; Acetylene: 7-15 psi
General Cutting Info
There is a wide variety of cutting tip styles and sizes available to suit various types of
work. The thickness of the material to be cut generally governs the selection of the tip.
The cutting oxygen pressure, cutting speed, and preheating intensity should be
controlled to produce narrow, parallel sided kerfs. Cuts that are improperly made will
produce ragged, irregular edges with adhering slag at the bottom of the plates. Table
below identifies cutting tip numbers, gas pressures, and hand-cutting speeds used for
cutting mild steel up to 12 in. (304.8 mm) thick.
Oxyacetylene Cutting Information
42
Plate Cutting tip Oxygen (psi) Acetylene Hand cutting

thickness (size number) (psi) speed (inches
(inches) per minute)
¼ 0 30 3 16 to 18
3/8 1 30 3 14.5 to 16.5
½ 1 40 3 12 to 14.5
¾ 2 40 3 12 to 14.5
1 2 50 3 8.5 to 11.5
1½ 3 45 3 6 to 7.5
2 4 50 4 5.5 to 7
3 5 45 4 5 to 6.5
4 5 60 5 4 to 5
5 6 50 5 3.5 to 4.5
6 6 55 6 3 to 4
8 7 60 6 2.5 to 3.5
10 7 70 6 2 to 3
12 8 70 6 1.5 to 2
Note: Check the torch manufactures data for tip identification number and optimum
pressure settings
Safety Precautions in Cutting Operations
1. Never use a cutting torch where sparks will be a hazard;
2. Sweep floors clean and wet them before cutting;
3. Provide a bucket of water or sand to catch dripping slag;
4. Use fire-resistant guards, partitions or screens if necessary;
5. Take extra precautions while working in greasy, dirty, or gaseous atmosphere to

prevent explosions;
6. Keep combustible materials at least 35 ft. away from cutting operations;
7. Never cut near ventilators;
8. Never use oxygen to dust off clothing or work pieces or as a substitute for
compressed air;
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9. Locate the nearest fire extinguisher before performing any welding or cutting
operation;
10. Purge oxygen and acetylene hoses before lighting torch;
11. Never move cylinders without protective caps in place;
12. Wear personal protective equipment. Wear welding gloves, helmet, leather
apron, welding chaps, leather shoes, welding goggles, and other personal
protective equipment to help prevent weld burns and injury. Make sure the
welding goggles or face shield have at least a No. 4 filter lens;
13. Do not wear clothing made of synthetic fibers while welding;
14. Fasten cylinders securely. Do not handle cylinders roughly. Chain cylinders in an
upright position to a wall or cart. When regulators are not on cylinders, keep
safety caps in place. Caps will prevent damage to cylinder valves;
15. Never use oil on welding equipment. Oil and grease may ignite spontaneously,
when in contact with oxygen;
16. Open cylinder valves correctly. Open the valve on the acetylene cylinder no more
than three-fourths of a turn (maximum one turn) so it can be closed quickly in
case of emergency. Open the valve on the oxygen tank fully. While welding or
cutting, leave the valve wrench in position;
17. Keep the tip pointed away from your body. Do not saturate your clothing with
oxygen or acetylene. Before and while lighting the flame, keep the tip pointed
away from your body;
18. Light the flame with an approved lighter. Using matches to light the torch brings
fingers too close to the tip;
19. Set the operating pressure carefully. Never use acetylene at a pressure over 15
psi;
20. Do not leave the work area until the cylinder valves are closed. Be sure the
cylinder valves are closed and pressure is relieved from the hoses before you
leave the work area;
21. Do not cut on containers that have held flammable materials;
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22. Store oxygen cylinders away from acetylene cylinders. A non-combustible wall at
least 5 feet high should be used to separate cylinders.
Applications
Oxygen cutting would be useful only for those materials which readily get
oxidized and the oxides have lower melting points than the metals. So it is most
widely used for ferrous materials.
Oxygen cutting is NOT used for materials like aluminum, bronze, stainless steel
which resist oxidation.
Cutting of high carbon steels and cast irons require special attention due to
formation of heat affected zone (HAZ) where structural transformation occurs.
Typical Facts about Gas Cutting:
1) The flame is not intended to melt the metal, but to bring it to its ignition
temperature. The oxygen flow rate is critical — too little will make a slow ragged
cut; too much will produce a wide concave cut. Oxygen lances and other custom
made torches do not have a separate pressure control for the cutting oxygen, so
the cutting oxygen pressure must be controlled using the oxygen regulator. The
oxygen cutting pressure should match the cutting tip oxygen orifice. Consult the
tip manufacturer's equipment data for the proper cutting oxygen pressures for the
specific cutting tip. (Oxy-acetylene torches can easily cut through ferrous
materials in excess of 2 inches and oxygen lances are used in scrapping
operations and cut sections thicker than 8 inches. A thermic lancer is a tool which
uses rapid oxidation of iron to cut through almost any material);
2) The oxidation of iron by gas cutting is highly exothermic. Once started, steel can
be cut at a surprising rate, far faster than if it was merely melted through. At this
point, the pre-heat jets are there purely for assistance. The rise in temperature
will be obvious by the intense glare from the ejected material, even through
proper goggles;
3) Since the melted metal flows out of the work piece, there must be room on the
opposite side of the work piece for the spray to exit. When possible, pieces of
metal are cut on a grate that lets the melted metal fall freely to the ground;
45
4) Oxy-acetylene cutting speed is usually twice as fast as a cut-off grinder. Besides,

an oxy-fuel torch is light, small and quiet and needs very little effort to use,
compared to a cut-off grinder, which is heavy, noisy and needs considerable
operator exertion and may vibrate severely. Cut-off grinders are useless for thick
sections;
5) Gas cutting can be done manually or by a machine. The manual cutting is used
for general purpose work and for straight line cutting. In machine cutting the torch
is mounted on a rail and both rail and the torch can move simultaneously along
the two mutually perpendicular axes in the horizontal plane with the help of servo
motors. Robotic oxy-fuel cutters provide flexibility to produce almost any shape
from large steel plates. There is provision to hold more than one torch so that
large number of identical pieces can be cut at the same time;
6) Hydrocarbon gases, such as propane, butane and LPG are also used for cutting
up scrap to save money as these gases are far cheaper than acetylene on BTU-
for-BTU basis. With a right torch (injector style), propane can make a faster and
cleaner cutting and is much more useful for heating and bending applications
than acetylene.
Note that hydrocarbon gases, such as propane, butane and natural gas, are NOT
suitable for welding ferrous materials due to their oxidizing characteristics.
46
SECTION – 4 SAFE WORKING PRACTICES
This section describes safe practices developed from experience in using welding and
cutting equipment. Continuous research, development, and field experience result in
reliable equipment and safe installation, operation, and servicing practices. Accidents
occur because of improper equipment use or maintenance. Some safe practices are
based on common sense; others may require technical volumes to explain. In any event,
rules should be followed.
Work Area
The work area must have a fireproof floor. Concrete is best;
Use heat resistant shields to protect walls and unprotected flooring from sparks
and hot metal;
Oxygen itself will not burn; however, the presence of pure oxygen will accelerate
combustion and cause materials to burn with great intensity;
Use tables with fireproof tops. Firebricks work well to protect table and bench
surfaces;
Chain or otherwise secure cylinders to a wall, bench or cart;
Keep the area between you and the cylinder valves unobstructed;
Keep cylinders clear of areas where they may be struck or knocked over.
Post “No Smoking” warning sign in area.
Hazardous Fume Accumulation & Ventilation
Maintain adequate ventilation to prevent the accumulation of toxic fumes and

gases; (Refer to ANSI Standard Z49-1);
Work in a confined space only while it’s being ventilated, or when wearing an air-
supplied respirator. Do NOT use oxygen for ventilation.
Protective Clothing
Wear protective clothing – gauntlet gloves, hat, and high safety toe shoes. Keep
shirt collar and pocket flaps buttoned and wear cuffless trousers to prevent entry
47
of sparks and slag. Hot metal such as welding rod, electrode stubs and work
pieces should never be handled without gloves;
Wear safety goggles or glasses with side shields, appropriate filter lenses or
plates (protected by clear cover glass). This is a MUST for welding or cutting
(and chipping), to protect the eyes from radiant energy and flying metal. Replace
cover glass when broken, pitted, or spattered. For eye protection refer ANSI Z
87.1;
Do not wear oily or greasy clothing while welding or cutting. They are readily
ignited by sparks;
Wear ear protection when working overhead or in a confined space. A hard hat
should be worn when others work overhead.
Fires and Explosions
Fire or explosion can occur if the equipment is improperly installed, repaired or

used. Be aware that: flying sparks or falling slag can pass through cracks, along
pipes, through windows or doors, and through wall or floor openings, out of sight
of the goggled operator. Sparks and slag can fly 35 feet;
Inspect oxy-fuel apparatus for oil, grease, or damaged parts;
Do not use the oxy-acetylene apparatus if oil or grease is present or if damage is

evident;
Never use oil or grease on or around any oxy-acetylene apparatus;
Keep flames, heat and sparks away from cylinders and hoses;
Have a fire extinguisher of proper type and size on hand in the work area, know
where they are located in the shop;
Open the oxygen valve all the way to seal the cylinder back seal packing;
Never test for leaks with a flame. Use soapy water;
After work is complete, inspect the area for any possible fires or smoldering
materials.
Fuel Leakage and Detection
48
Joints and hoses should be checked for leaks before any welding is attempted.
Whilst acetylene may be detected by its distinctive smell (usually at levels of less
than 2%) oxygen is odorless;
Leak detection is best carried out applying a weak (typically 0.5%) solution of a
detergent in water or a leak detecting solution from one of the gas supply
companies. It is applied to the joints using a brush and the escaping gas will form
bubbles. On curing the leak, the area should be cleaned to remove the residue
from the leak detecting solution.
Use of Oxygen
Always refer to oxygen by correct name; Say “oxygen”, never “air”. It is very
important that oxygen not be confused with compressed air, or used as a
substitute for compressed air;
Oxygen is not flammable but even materials that do not burn in air usually burn in
oxygen. Those that burn slowly in air can ignite easily and burn violently in an
oxygen enriched atmosphere;
Never use oxygen to ventilate confined spaces. Use air to replace atmospheric
oxygen consumed by welding or cutting. Oxygen-enriched (> 23%) or oxygen-
depleted (<19%) atmospheres should be avoided;
Never saturate clothes with oxygen. Clothing saturated with oxygen will burn
intensely when ignited;
Grease, oil, oil-bearing materials, greasy gloves and rags, and other
combustibles that can readily ignite in the presence of oxygen must be kept from
any oxygen equipment;
Keep oxygen cylinders at least 20 feet from fuel gas cylinders or other readily
combustible materials particularly grease or oil OR separated by a five foot non-
combustible barrier having a fire resistance rating of at least ½ hour);
If liquid oxygen is used, cylinders must be transported, stored and used in upright
position to maintain gaseous state for safety devices, and to prevent liquid from
reaching regulator.
Use of Acetylene Gas
49
Refer to fuel gas by its correct name. Say “acetylene”, not “gas”. The other gases
– natural gas, methane, or the liquefied petroleum (LP) gases, propane and
butane – differ from acetylene, and from each other, in heat content, flammability
limits, and safe handling requirements. Therefore, be specific when you refer to
any gas;
Acetylene cylinders must be transported, stored, and used in upright position to

avoid discharge of acetone with the gas during use;
CGA 5.3.3.13 or G-1 calls for a withdrawal rate “not to exceed 1/10(one-tenth) of
the capacity of the cylinder per hour during intermittent use. For full withdrawal of
the contents of the cylinder on a continuous basis, the flow rate should be no
more than 1/15 (one-fifteenth) of the capacity of the cylinder per hour”;
If cylinder valves leaks, immediately close valve on fuel gas cylinder. If valve still
leaks immediately, remove cylinder outdoors, away from possible source of
ignition and notify cylinder supplier at once;
Acetylene cylinder wrench should be left on an open cylinder valve and removed
after closing valve. Use only approved wrench, available from cylinder supplier.
Pressure regulators
NEVER withdraw gas from a cylinder or pipeline except through an approved

pressure reducing regulator;
Regulator relief valve is designed to protect only the regulator from overpressure;
it is not intended to protect any downstream equipment. Provide such protection
with one or more relief devices;
Never connect a regulator to a cylinder containing gas other than that for which
the regulator was designed;
Remove regulator from cylinder when transporting unsecured on a cart not

designed for such purpose;
The following symptoms indicate a faulty regulator:
o Leaks - if gas leaks externally.
o Excessive creep - if the regulator delivery pressure continues to rise with

downstream valve closed.
50
o Faulty gauge - if gauge pointer does not move off “stop” pin when
pressurized, nor return to “stop” pin after pressure release.
Cylinders
Cylinders must be handled carefully to prevent leaks and damages to their walls,
valves, or safety devices: a. Avoid electrical circuit contact with cylinders
including third rails, electrical wires, or welding circuits. They can produce arcs
that may damage the cylinder wall, causing a possibly serious accident. Never
strike an arc on a cylinder;
Identifying gas content; Use only cylinders with name of gas marked on them; do
not rely on color of cylinder to identify contents. Notify supplier if content of
cylinder is not clearly identifiable. Never deface or alter name, number, or other
markings on a cylinder. It is illegal and hazardous;
Never use a cylinder or its contents for other than its intended use. Never use as
a support, roller, or clothes rack;
Secure from falling. Always chain or secure cylinders upright when a regulator
(and hose) is connected to it;
Transporting cylinders. With a crane, use a secure support such as a platform or

cradle designed for the purpose. Do NOT lift cylinders off the ground by their
valves or caps, or by chains, slings, or magnets;
Do NOT expose cylinders to excessive heat, sparks, slag, and flame, etc. that
may cause rupture;
Do not allow contents to exceed 130°F;
Protect cylinders, particularly valves from bumps, falls, falling objects, and
weather. Keep caps securely tightened on cylinders not in use or being moved.
Stuck valve. Do NOT use a hammer or metal wrench (except special key for
acetylene) to open a cylinder valve that cannot be opened by hand. Notify your
supplier;
Cylinder fittings should never by modified or used for other than their intended
purpose.
Torch
51
Examine seating surface of torch and connections before use for ear and
damage. Worn or damaged parts should be replaced;
Do not attempt repair of torches (or regulators). If faulty, send them for repair to
manufacturer’s designated repair center where special techniques, tools and
tests are used by trained personnel;
Torch is not a hammer. Never use it to chip slag. Such misuse can distort torch
or tip to create hazards. Use appropriate tool for the job;
Torch tip cleaning should be done only with specifically-designed cleaning tip
orifices to avoid enlarging or damaging the exit holes.
Hoses
NEVER use hose other than that designed for the specified gas. A general hose
identification rule is: red for fuel gas, green for oxygen, and black for inert
gases;
Use RMA-CGA Grade T hose for fuel gas (including acetylene) to prevent hose
failures. Grades R and RM are for use with acetylene only;
Use ferrules or clamps designed for the hose (not ordinary wire or other
substitute) to connect hoses to fittings;
Use only standard brass fittings to splice hose. No copper tubing splices;
Avoid long runs to prevent kinks and abuse. Suspend hose off ground or protect
it from damage by vehicles, sparks, slag or open flames;
Examine hose regularly for leaks, wear, and loose connections. Immerse
pressured hose in water; bubbles indicate leaks;
Repair leaky or worn hose by cutting out damaged area and splicing. Do NOT
use tape.
Proper Connections
Clean cylinder valve outlet of impurities that may clog orifices and damage seats
before connecting regulator;
Match regulator to cylinder. Before connecting, be sure the regulator label and
cylinders marking agree, and the regulator inlet and cylinder outlet connections
are proper for the intended service;
52
Do not use pipe compound or lubricant. Tighten but do not force connection. If
connection leaks, close cylinder valve, depressurize line. Disassemble, clean,
and retighten the valve. For metal-to-metal seating, use correct wrenches,
available form your supplier. For O-ring connections, hand-tighten;
Avoid using adapters between cylinder and regulator, but if unavoidable, use a
CGA adapter (available from your supplier). Use two wrenches to tighten adapter
with both right and left hand threads;
Regulator outlet (or hose) connections may be identified by right hand threads
for oxygen and left hand threads (with grooved hex on nut or shank) for fuel gas.
Safety in Operation & Use
• Acetylene is unstable at pressures above 15 PSI;
• NEVER release acetylene, or any other fuel gas in confined spaces, where it
might cause a fire or explosion;
• DO NOT open an acetylene cylinder valve more than one turn. This permits
adequate flow of acetylene from the cylinder and allows for quick closing of the
valve in an emergency situation;
• To open and close acetylene cylinder valves not provided with hand-wheels,
always use the special wrench or key provided by the supplier. Leave the wrench
or key in position, ready for immediate use should it be necessary to close the
valve promptly. (When several cylinders are manifold together, a wrench on
every cylinder is not required.)
• More than 1/10 the capacity of the cylinder should not be used per hour. This
causes the acetylene to rapidly come out of solution, like carbon dioxide bubbles
violently fizzing from a fizzy soft drink that has just been shaken;
• Oxygen cylinder contains pressures over 2000 PSI and must be handled
carefully;
• Pure oxygen will accelerate combustion to the point that it can cause an
explosion;
• Do not use oxygen to dust off clothing or the work area;
53
• Use the correct size wrench when tightening or loosening fittings. They are made
of brass and can be damaged easily;
• When not in use, cylinder must have a protective cap installed;
• NEVER use a cylinder that is leaking. If leakage around the cylinder valve stem
is detected after the valve has been opened (one and one-half turns for an
acetylene cylinder, as far as possible for an oxygen cylinder) close the valve tight
and return it to your supplier after tagging the cylinder to tell him that the valve is
unserviceable;
• Stand to the side of the equipment when opening the cylinder valves, and open
them slowly. This will limit the risk of injury due to exploding regulators;
• Only use a friction lighter to light your torch;
• Hot metal left out should be marked “HOT” so the others will not be burned by it;
• Use pliers or tongs to grab hot metal;
• Do not weld or cut on a closed container;
• Inspect the hoses frequently and when necessary replace them;
• ALWAYS keep oxygen and acetylene cylinders vertical upright at all times. Do
not store them in the horizontal position; if an acetylene cylinder is used in the
horizontal position, solvent may be lost and flame quality may be affected;
• Store oxygen cylinders separately from fuel gas cylinders. Unless a fire-resistant
noncombustible partition, at least 5 feet high, is used to separate the two types of
cylinders or a minimum 20-foot separation should be maintained;
• Oil, grease, coal dust, and similar organic materials are easily ignited and burn
violently in the presence of high oxygen concentrations. Never allow such
materials to come in contact with oxygen or oxy-acetylene equipment, including
hose. Oxy-acetylene apparatus does not require lubrication;
• DO NOT use pipe-fitting compounds or thread lubricants for making connections.

Connections for oxyacetylene and oxygen-fuel gas equipment are designed so
that they can be made up tight without the need for lubricants or sealants. Of
special importance is the need to keep all materials containing oil and grease
away from equipment that uses oxygen.
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Lighting Torch
• Purge lines daily before lighting to remove air and other contaminants from
hoses. Open each torch valve in turn long enough for the pure gas to purge out
any gas mixtures. Shut one valve before opening the other. Do NOT purge in a
confined space, in the presence of flame or other source of ignition, or toward
people;
• Point tip away from yourself and others when lighting and using torch;
• Use spark lighter or pilot light to light torch. Do NOT use matches or cigarette
lighter, hand burns may result;
• Light as follows: Open fuel valve and ignite gases flowing from tip. Adjust fuel
valve for full flow without blowing off. Adjust oxygen valve to desired flame.
Extinguishing Flame:
• Close oxygen and (without delay) fuel torch valves tightly;
• Check for gas leak from tip or valves;
• Leave torch in safe position to prevent accidental dislodging that may open
valves or cause damage;
• Leaving Equipment unattended (lunch or overnight):
o Extinguish flame by closing torch valves;
o Close cylinder valves.
• Leaving equipment unattended (over weekend or longer):
o Extinguish flame by closing torch valves and close cylinder valve;
o Drain gas from regulators by opening torch valves, venting gases in safe
direction, then closing valves one at a time. If in public area, disconnect and
store equipment to prevent unauthorized or accidental use, which may create
a hazard;
o Purge lines before lighting or reuse.
Backfires and Flashbacks
55
A backfire is a loud noise produced by the explosion of gases at the cutting or welding
tip usually following a minor flashback of the flame, extinguishment, and re-ignition at the
tip. Repeated backfire can cause tip to overheat and eventually cause a sustained
flashback. Causes are:
o Bringing tip too close to work or touching it;
o Foreign particles entering tip and impeding gas flow;
o Overheated tip, such as caused by working in corners;
o Trying to operate with incorrect or too low a gas flow.
Backfire remedy
If torch does not stay lit, close oxygen gas and fuel gas valves - in that order. Re-light
fuel gas with spark lighter only. If stable flame is not obtained by adding oxygen, close
torch valves, check tip cleanliness and regulator settings, purge, and relight.
Flashback and its causes
A flashback is a burning back of the flame into the tip, or into or through the torch. It is
also called a sustained burning in tip or torch. A flashback can be caused by faulty or
misused equipment. If it doesn’t cause fire or hose rupture, then it may produce a
hissing or squealing due to burning inside torch or tip (usually at the mixer). Examples of
faulty or misused equipment are:
o Failure to purge.
o Incorrect pressures.
o Distorted or loose tips or adapter seats.
o Kinked hoses.
o Clogged tip or torch orifices.
o Overheated tip or torch.
To stop a flashback:
Do NOT touch any parts of the tip, mixer, or extension that may be hot;
When squealing sound is heard: the internal combustion must be extinguished

immediately by shutting off torch fuel gas and oxygen valves in that order;
56
Wait a MOMENT, OR UNTIL NO SQUEALING is heard on reopening fuel gas

valve, then relight;
When squealing is not heard (and flashback is indicated by flow of hot gases
from tip): flame is inside the torch. Immediately shut off cylinder valves and wait.
After five minutes, if torch, regulator, and cylinder are cool, disconnect equipment
and inspect torch and regulator for inner damage.
Chemical exposure
A less obvious hazard of welding is exposure to harmful chemicals. Exposure to certain

metals, metal oxides, or carbon monoxide can often lead to severe medical conditions.
Damaging chemicals can be produced from the fuel, from the work-piece, or from a
protective coating on the work-piece.
Lead-, Cadmium-, Zinc-, Mercury-, and Beryllium-bearing and similar materials,

when welded (or cut) may produce harmful concentrations of toxic fumes. Long-
term exposure to beryllium may result in shortness of breath, chronic cough, and
significant weight loss, accompanied by fatigue and general weakness. Adequate
local exhaust ventilation must be used, or each person in the area as well as the
operator must wear an air-supplied respirator. For beryllium, both must be used;
Other alloying elements such as arsenic, manganese, silver, and aluminum can
cause sickness to those who are exposed. Metals coated with or containing
materials that emit toxic fumes should not be heated unless coating is removed
from the work surface, the work area is well ventilated, or the operator wears an
air-supplied respirator;
More common are the anti-rust coatings on many manufactured metal

components. Zinc, cadmium, and fluorides are often used to protect irons and
steels from oxidizing. Galvanized metals have a very heavy zinc coating.
Exposure to zinc oxide fumes can lead to a sickness named "metal fume fever".
This condition rarely lasts longer than 24 hours, but is still unpleasant.
Vapors from chlorinated solvents can be decomposed by the flame heat to form
PHOSGENE, a highly toxic gas, and other lung and eye-irritating products. The
ultraviolet (radiant) energy of the arc can also decompose trichloroethylene,
perchlorethylene and other chlorinated solvent vapors to form phosgene. DO
NOT WELD or cut where solvent vapors can be drawn into the welding or cutting
57
atmosphere or where radiant energy can penetrate to atmospheres containing

even minute amounts of the solvent vapors;
(Data from Occupational Safety and Health Administration)
Additional information regarding welding and cutting safe practices can be found in
Standards and Pamphlets published by ANSI, NFPA (standard 51), AWS, and CGA. The
National Electrical Code, Occupational Safety and Health Administration and local
industrial codes also provide mandatory requirements for equipment installation, use,
and service.
CASE STUDY
This case study is presented for people who use acetylene for welding, cutting and
similar processes. It provides information on the fire and explosion hazards of acetylene.
Acetylene cylinder explosion
An operator was lighting an oxy/acetylene cutting torch. There was a flashback to the
acetylene cylinder, which started to vibrate. Three minutes later the cylinder exploded.
The cylinder split into two parts. The largest part shot through a window and travelled 23
meters before embedding itself in an embankment at the factory boundary.
The workshop was badly damaged. The windows were blown out and the roof collapsed.
The explosion also lifted the roof of the main factory building, which had to be replaced.
The cost of the damage was over £1 million.
Fortunately, no-one was injured, because the operator realized that the cylinder was in a
dangerous condition. He raised the alarm and the factory was immediately evacuated.
What went wrong?
The operator did not fully appreciate the hazards of acetylene. He did not follow the
recommended procedures or take adequate precautions. In particular:
1. The correct lighting up procedure was not followed. The gas hoses were not
purged.
2. The acetylene gas was not at the correct pressure.
3. The gas cylinders were not protected with flashback arresters.
A flashback can occur…if there is a flammable mixture of fuel gas and oxygen in the
hoses when the torch is lit. If it is not stopped, the flame will ignite the mixture and will
58
travel backwards from the torch, along the hoses, through the regulator and into the
cylinder. A flashback can trigger decomposition of the acetylene in the fuel hose, in the
regulator and in the cylinder itself.
Hazards of acetylene cylinders
There are a number of incidents each year where a flashback into an acetylene cylinder
triggers decomposition, leaving the cylinder in a dangerous, unstable condition. An
explosion of the cylinder only three minutes after a flashback is extremely rare. In most
cases, if the decomposition is identified at an early stage, there is time for the building to
be evacuated, the fire brigade to be called and for emergency action to be taken.
To make an unstable cylinder safe, the fire brigade may have to apply cooling water for
many hours. It could be several days before the cylinder can be moved, because moving
the cylinder could restart or accelerate the decomposition.
These incidents put at risk anyone in the vicinity of the cylinder and anyone who tries to
make the cylinder safe, such as the emergency services.
Acetylene cylinders can be used safely
An acetylene cylinder has a different design from most other gas cylinders. It consists of
a steel shell containing a porous mass. The porous mass is a cellular structure which
completely fills the cylinder. The acetylene gas in the cylinder is dissolved in acetone
which is absorbed by the porous mass. Decomposition of the acetylene is usually
triggered by heat. For example, if the cylinder is:
1. Involved in a fire;
2. Scorched by flames from a blowtorch; or
3. Involved in a flashback.
The porous mass is designed to slow down or stifle any decomposition of the gas. From
the start of decomposition to the cylinder exploding should take several hours. This will
usually (but not always) provide time for emergency action.
Decomposition can be triggered more easily and can proceed more rapidly if:
1. The porous mass has been damaged by repeated flashbacks or by mishandling

or dropping the cylinder;
59
2. The cylinder valve is leaking gas (an open or leaking valve increases the rate of
decomposition within the cylinder); or
3. The acetylene in the hoses is above the pressure recommended by the supplier.
For most welding and cutting processes, the acetylene pressure should not
exceed 9 psi.
What can you do to prevent flashback?
Training
Do not use oxy/acetylene equipment unless you have been trained.
Use the correct lighting-up procedures
Before lighting the blowpipe, purge the hoses by opening the gas supply to each hose
for a few seconds. This will flush out any flammable mixtures of gases in the hose.
Purge one hose at a time and close the blowpipe valve after purging. Use a well-
ventilated area.
Maintain non-return valves
• Fit non-return valves (often called check valves) on the torch, to prevent back-
feeding of gas into the hoses.
• Inspect regularly and replace damaged non-return valves. Note: non-return

valves will not stop a flashback once it has occurred.
Keep nozzles in good condition
Poorly maintained nozzles cause turbulent gas flow, which increases the risk of
flashback.
• Inspect nozzles regularly. Make sure they are not blocked by dirt or spatter.
Replace damaged nozzles.
• Do not hold the nozzle too close to the workpiece. The nozzle can overheat and
cause a flashback.
If a flashback does occur:
• Immediately close the cylinder valves, both acetylene and oxygen, if it is safe to
do so. The flame should go out when the fuel gas (acetylene) is shut off. If the
60
flame cannot be put out at once, evacuate the area and call the emergency fire
services and the gas supplier.
• Check any acetylene cylinder which has been involved in a flashback or which
may have been affected by fire or flames. If it becomes warm or starts to vibrate,
evacuate the building immediately and call the emergency fire services. Also call
the gas supplier.
• Do not attempt to move an unstable cylinder. Direct water spray at the cylinder
body, if it is safe to do so.
• Before using again, check flashback arresters and other components which may
have been damaged by the flashback. Replace if necessary. If in doubt, consult
the supplier.
Backfire or flashback procedure
After an un-sustained backfire in which the flame is extinguished:
Close the blowpipe control valves (fuel gas first);
Check the nozzle is tight;
Check the pressures on regulators;
Re-light the torch using the recommended procedure;
If the flame continues to burn:
Close the oxygen valve at the torch (to prevent internal burning);
Close the acetylene valve at the torch;
Close cylinder valves or gas supply point isolation valves for both oxygen and
acetylene;
Close outlets of adjustable pressure regulators by winding out the pressure-

adjusting screws;
Open both torch valves to vent the pressure in the equipment;
Close torch valves;
Check nozzle tightness and pressures on regulators;
Re-light the torch using the recommended procedure
61
If a flashback occurs in the hose and equipment, or fire in the hose, regulator
connections or gas supply outlet points:
Isolate oxygen and fuel gas supplies at the cylinder valves or gas supply outlet
points (only if this can be done safely);
If no risk of personal injury, control fire using first aid fire-fighting equipment;
If the fire cannot be put out at once, call emergency fire services after the
equipment has cooled, examine the equipment and replace defective
components.
When a backfire has been investigated and the fault rectified, the torch may be re-lit.
After a flashback, because the flame has extended to the regulator it is essential not only
to examine the torch, but the hoses and components must be checked and, if necessary,
replaced. The flashback arrestor should also be checked according to manufacturer's
instructions and, with some designs, it may be necessary to replace it.
Note: The fitting of flashback arresters is not a substitute for safe working practices.
Always read and understand these safe practices before attempting to install, operate or
service the equipment. Comply, as applicable, with the practices for particular equipment
used, and their instruction manuals for personal safety and the safety of others. Failure
to observe these safe practices may cause serious injury or death. Habitual safety
promotes confident equipment use.
62
Annexure - 1
Terminology
1) Acetone: A flammable liquid used in acetylene cylinders to dissolve and store

acetylene.
2) Acetylene: A colorless, flammable gas that is used in oxyfuel welding. Acetylene is

the most commonly used gas for mixing with oxygen to fuel oxyfuel torches.
3) Airtight: Not allowing any gases or air to penetrate. An airtight joint will not leak
any gas.
4) Aluminum: A silvery white metal that is soft, light, and has a high strength-to-
weight ratio. Aluminum is one of the most difficult metals to weld.
5) Arc welding: A joining process that uses electricity to generate the heat needed to
melt the base metals.
6) Braze pool: The pool formed by the melted filler metal during braze welding. The
temperature to melt the filler metal is low enough that the pieces being joined do
not melt.
7) Braze welding: A process in which a filler metal is melted at a temperature above

840° F (450° C), but below the melting point of the base metals to fill in a gap
between two base metals. Braze welding differs from brazing because the filler
metal is used to fill a gap.
8) Brazing: A joining process that is used to combine dissimilar metals at

temperatures lower than welding.
9) Butt joint: A joint formed by joining two pieces of metal edge to edge.
10) Capillary action: The ability of a substance to draw a liquid upwards against the
force of gravity. In brazing, capillary action causes a filler metal to be drawn into
the space between work pieces.
11) Copper: A reddish metal that is very ductile, thermally and electrically conductive,
and corrosion resistant. Copper can be welded using limited methods.
12) Cutting: The use of an oxyfuel torch to separate metal from a workpiece. Oxyfuel
cutting uses an additional high-pressure stream of oxygen to cut metal.
A-1
13) Cylinder: A container for compressed gases. Each gas is stored in a unique type
of cylinder.
14) Die: A reusable mold that holds heated liquid metal and imparts its shape as the
metal cools. Oxygen cylinders are shaped in dies.
15) Distillation: The process by which oxygen is extracted from the air to be stored in
a cylinder.
16) Ductility: The ability of a metal to be drawn, stretched, or formed without breaking.
17) Edge joint: A joint formed by joining the edges of two pieces of metal that are
parallel to each other.
18) Ferrous metal: A metal that contains iron. Ferrous metals are the most common
type of welded metal.
19) Filler metal: A type of metal sometimes added to the joint in fusion welding. Filler
metal adds to the strength and mass of the welded joint.
20) Flashback: A torch malfunction in which the flame briefly or continually moves up
into the torch and hoses. If a flame reaches the hoses, an explosion can occur.
21) Flashback arrestor: A part of an oxyfuel outfit that is installed between the hoses
and the torch. A flashback arrestor reduces the chances of flashback occurring
while a torch is used.
22) Flux: A non-metallic material used to protect the weld puddle and solid metal from
atmospheric contamination.
23) Hose connector: The part of an oxyfuel torch where the flashback arrestor is
attached to the torch.
24) Impurities: Any elements contained in an oxyfuel weld that are not the metal being
joined or the filler metal.
25) Injector: The part of an injector torch that pulls low-pressure acetylene into the
torch and mixes it with oxygen.
26) Injector torch: A type of torch that uses lower-pressure acetylene and features an
internal injector that pulls the acetylene into the torch.
27) In-tip mixer: A welding tip that contains a mixing chamber as part of the tip.
A-2
28) Joining: Bringing two separate materials together through some type of forming.
Joining is one of the main ways metals can be formed.
29) Lap joint: A joint formed by two overlapping pieces of metal.
30) Low-carbon steel: Carbon steels that contain less than 0.3% carbon. Also
referred to as mild steel, low-carbon steel is the most commonly welded metal.
31) MAPP gas: Also called methylacetylene-propadiene gas. A liquefied petroleum

gas that can be used in oxyfuel processes. The main disadvantage of MAPP gass
is that it costs much more than acetylene.
32) Metal: A hard, crystalline solid that conducts electricity and heat. It is shiny when
polished, and it can be hammered, bent, formed, and machined.
33) Mixing chamber: A part of an oxyfuel outfit that is connected to the tip of the torch,
or is part of the tip. The mixing chamber is where the two gases are combined
before being burned by the flame.
34) Non-ferrous metal: A metal that does not contain iron. Nonferrous metals are
more difficult to weld than ferrous metals.
35) Orifice: The hole or holes at the end of a torch tip. The shape and number of holes
determine the use of the tip.
36) Outside corner joint: A joint formed by the edges of two metal pieces being
welded together at an angle of around 90 degrees. The weld is done on the outside
of the corner.
37) Oxide: A chemical compound containing oxygen and one other element. Oxides
form during oxyfuel welding is harmful to the weld.
38) Oxy-fuel welding: A joining process that uses a mix of gases to fuel a torch to join
two metal parts.
39) Oxygen: A nonmetallic element that is colorless, odorless, and tasteless. Oxygen
is one of the two gases used in oxyfuel welding.
40) Porous: Full of holes that allow the material to absorb liquids. The material inside
an acetylene cylinder is porous, enabling it to hold acetone.
41) Positive pressure torch: A torch that uses equal pressures of oxygen and
acetylene and does not have an injector.
A-3
42) Propylene: Also known as propane. A flammable gas that can be used in oxyfuel
welding instead of acetylene.
43) Soldering: A joining process in which a filler metal is melted at temperatures

below 840° (450° C) to form a joint between two base metals. Soldering is often
used for delicate projects such as jewelry and electronics.
44) Stainless steel: A type of steel that contains more than 15% chromium and
exhibits excellent corrosion resistance. Stainless steel can be welded using many
methods.
45) T-joint: A joint formed when the edge of one piece is welded to the surface of
another piece at a 90° angle.
46) Torch: A tool used to generate the flame for oxyfuel welding by mixing oxygen and
a fuel gas, usually acetylene.
47) Torch body: Also called the handle. The part of the torch held by the welder.
Inside the torch body are hoses which direct the flow of gases to the mixing
chamber.
48) Unstable: Highly reactive and dangerous, possibly explosive. Unstable chemicals
require careful handling to ensure safety.
49) Valve: The part of the torch used to regulate the amount of oxygen and fuel gas
flowing into the torch.
50) Watertight: Not allowing any liquids to penetrate. A watertight joint will not leak
any liquids at all.
51) Welding rod: Also know as a filler metal. Filler metals come in rods that are used
during the welding process.
52) Welding tip: The end of the torch where the flame is ignited. Tips are usually
interchangeable, and are made of solid copper.
A-4

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Fundamentals of Gas Cutting and

Course No: D06-002

Continuing Education and Development, Inc.

GAS WELDING AND CUTTING

Oxy-fuel welding, commonly referred to as oxy welding or gas welding is a process of

Chemistry of Oxy Acetylene Process

2C2H2 + 2O2 = 4CO + 2H2 + Heat ---------- (1)

4CO + 2H2 + 3O2 = 4CO2 + 2H2O + Heat--------- (2)

2C2H2 + 5O2 = 4CO2 + 2H2O + Heat ----------- (3)

Oxy Fuel welding Gases

a. High flame temperature

b. High rate of flame propagation

c. Adequate heat content

*Kindling Temperature – Kindling temperature is the lowest temperature at which a

substance bursts into flame.

MAPP gas is a registered product of the Dow Chemical Company. It is liquefied

Gasses suitable for cutting but NOT welding:

6) Net heat value of 1433 BTU per cubic foot;

Advantages of Oxyacetylene Process

1) Does not require electricity;

2) The equipment is portable, easy to transport;

5) Dissimilar metals can easily be joined;

1) Acetylene becomes extremely dangerous if used above 15 pounds pressure.

2) The process is typically slower than the electrical arc-welding processes;

Section -1 Oxy-Acetylene Apparatus

Section -2 Oxy-Acetylene Welding

Section -3 Oxy-Acetylene Cutting

Section -4 Oxy-Acetylene Safety & Precautions including case study

SECTION - 1 OXY-ACETYLENE APPARATUS

Oxy-acetylene welding outfit

The basic equipments used to carry out gas welding are:

1. Oxygen gas cylinder (green)

2. Acetylene gas cylinder (maroon/red)

3. Oxygen pressure regulator

4. Acetylene pressure regulator

5. Oxygen gas hose(Blue)

6. Acetylene gas hose(Red)

8. Trolleys for the transportation of oxygen and acetylene cylinders

9. Set of keys and spanners

10. Filler rods and fluxes

OXYGEN GAS CYLINDER

o 244 cu ft (for industrial plants);

Oxygen Cylinder Valves

o The valve must be opened all the way when in use.

ACETYLENE GAS CYLINDER

In an oxygen cylinder there is a precise relationship between cylinder pressure and

Safety Devices on Acetylene Cylinder

An acetylene cylinder is protected by number of fusible plugs, which melt at 220°F

o DO NOT adjust, alter, change, build, or do any experimental work on cylinders,

o DO NOT lift cylinders by the caps or valves;

o DO NOT transport the cylinders without the caps in place;

o Cylinders must be stored in upright position;

o KEEP valves closed on empty cylinders;

o NEVER transport with the regulators in place;

Manifold System for Gas Welding

1. There is no anti flashback device in an oxygen manifold system.

3. An oxygen pressure regulator is used in an oxygen manifold system.

Advantages of Using Manifolds –

a) The possibility of accidents is reduced.

More space is available at each workplace.

In case of fire, one can easily reach the cylinders.