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OXYACETYLENE WELDING

OXYACETYLENE WELDING. After completing this unit the student should be able to: * Identify components of an oxy-acetylene welding station. * List safety hazards association with oxy-acetylene welding. * To properly set-up and oxy-acetylene welding unit.

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OXYACETYLENE WELDING

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  1. OXYACETYLENE WELDING After completing this unit the student should be able to: * Identify components of an oxy-acetylene welding station. * List safety hazards association with oxy-acetylene welding. * To properly set-up and oxy-acetylene welding unit. * To properly shut down and oxy-acetylene welding unit. * Identify accessories used in oxy-acetylene welding. CONTINUE

  2. FOR INFORMATION ABOUT EACH PART OF THE OXYACETYLENE UNIT “CLICK “ ON THE ASSEMBLY SAFETY RULES ! ACCESSORIES UNIT SET- UP UNIT SHUT DOWN TEST YOUR KNOWLEDGE

  3. THE ACETYLENE REGULATOR CONSIST OF TWO GAGES AND THE ADJUSTING SCREW. ACETYLENE REGULATORS ARE FITTED WITH A MALE THREAD THAT IS LEFT HANDED SO THAT IT CAN NOT BE FITTED TO AN OXYGEN BOTTLE. CLICK ON A PART OF THE REGULATOR FOR ADDITIONAL INFORMATION.

  4. AN OXYGEN BOTTLE THE OXYGEN BOTTLE CONTAINS OVER 2,200 POUNDS PER SQUARE INCH OF PRESSURE! WHEN STORED IT MUST HAVE A CAP PROTECTING THE CYLINDER VALVE AND MUST BE SECURELY CHAINED IN AN UPRIGHT POSITION WHEN IN SERVICE.

  5. ACETYLENE BOTTLE THE ACETYLENE BOTTLE CONTAINS BOTH ACETONE AND ACETYLENE. ACETYLENE IN UNSTABLE AT PRESSURES ABOVE 15 P.S.I. AND ACETONE IS USED TO STABILIZE THE ACETYLENE. ACETYLENE CYLINDERS SHOULD BE STORED IN AN UPRIGHT POSITION WITH THE CYLINDER CAP IN PLACE. ALL ACETYLENE FITTINGS HAVE LEFT HANDED THREADS TO PREVENT BEING MIXED WITH OXYGEN EQUIPMENT

  6. OXYGEN REGULATOR THE OXYGEN REGULATOR CONSIST OF TWO GAGES AND THE ADJUSTING SCREW. OXYGEN REGULATORS ARE FITTED WITH A FEMALE THREAD THAT IS RIGHT HANDED SO THAT IT CAN NOT BE FITTED TO AN ACETYLENE BOTTLE. CLICK ON A PART OF THE REGULATOR FOR ADDITIONAL INFORMATION.

  7. WELDING HOSES THE OXYGEN ACETYLENE UNIT IS COMPRISED OF TWO DIFFERENT HOSES THAT ARE COLOR CODED. THE RED HOSE IS FOR ACETYLENE AND THE GREEN HOSE IDENTIFIES OXYGEN. ALL GAS FITTINGS ARE LEFT HAND THREADS WHILE OXYGEN FITTINGS ARE RIGHT HAND THREADS.

  8. QXY-ACETYLENE SAFETY RULES 1. 2. 3. 4. 5. 6. 7.

  9. CUTTING TORCH THE CUTTING TORCH IS USED TO CUT FERROUS METALS FROM 1/8 “ TO 12” THICK. IT USES RAPID OXIDATION TO REMOVE METAL LEAVING A KERF. THE TORCH TIP IS REMOVABLE ALLOWING VARYING THICKNESS OF METAL TO BE CUT. AS A GENERAL RULE THE OXYGEN PRESSURE INCREASES WHEN USING A CUTTING ATTACHMENT.

  10. WELDING NOZZLE THE WELDING TIP IS USED FOR WELDING AND BRAZING. THEY ARE AVAILABLE IN VARIOUS SIZES FROM 000 FOR 1/32” STEEL TO A # 12 WHICH IS CAPABLE OF WELDING MILD STEEL MATERIAL TO 4” THICK

  11. ROSE BUD OR MULTI-FLAME THE MULTI-FLAME OR ROSEBUD IS USED IN HEATING APPLICATIONS AND REQUIRES ACETYLENE PRESSURES OF 10-15 P.S.I.

  12. TIP CLEANERS THE TIP CLEANER IS USED TO CLEAN WELDING TIPS. USE THE RIGHT SIZE TIP CLEANER FOR A GIVEN SIZE TIP. DO NOT FORCE A LARGER TIP CLEANER IN A WELDING NOZZLE AS IT WILL RUIN THE WELDING TIP.

  13. THE FLASHBACK ARRESTOR OR CHECK VALVE IS A SAFETY DEVICE THAT SHOULD BE INSTALLED ON ALL OXY-ACETYLENE WELDING UNITS. THE DEVICES PREVENT THE REVERSE FLOW OF GASES. IF ACETYLENE AND OXYGEN WERE TO COMBINE ANYWHERE IN THE UNIT AN EXPLOSION WOULD RESULT WITH SERIOUS CONSEQUENCES.

  14. THE CYLINDER VALVE IS USED TO START THE FLOW OF ACETYLENE OR OXYGEN FROM THE CYLINDER. OXYGEN VALVES SHOULD BE OPEN ALL THE WAY WHILE ACETYLENE VALES SHOULD BE OPEN ½ TO ¾ OF A TURN

  15. THE ADJUSTMENT SCREW CONTROLS THE AMOUNT OF PRESSURE ON THE WORKING SIDE OF BOTH THE OXYGEN REGULATOR AND THE ACETYLENE REGULATOR. TURN THE SCREW IN TO INCREASE PRESSURE AND “BACK-OUT” THE SCREW TO DECREASE PRESSURE.

  16. THE CYLINDER PRESSURE GAUGE SHOWS THE REMAINING PRESSURE IN THE CYLINDER. IT IS SIMILAR TO THE GAS GAUGE IN YOUR CAR. AS THE NEEDLE NEARS ZERO (AROUND 100 psi) THE CYLINDER MUST BE RE-FILLED.

  17. THE WORKING PRESSURE GAUGE SHOWS THE PRESSURE DELIVERED TO THE WELDING TIP. THIS PRESSURE MAYBE ADJUSTED BY THE OPERATOR BY MOVING THE WINGED ADJUSTING NUT IN OR OUT OF THE REGULATOR. NOTE THE RED LINE ABOVE 15 PSI. ACETYLENE PRESSURES SHOULD NEVEREXCEED 15 PSI AS IT BECOMES UNSTABLE AND MAY EXPLODE!

  18. THIS SERIES OF SLIDES WILL INSTRUCT YOU IN THE PROPER SET-UP PROCEDURE FOR AN OXYACETYLENE WELDING UNIT. IT IS ESSENTIAL THAT YOU FOLLOW THIS PROCEDURE TO PREVENT A MIXTURE OF OXYGEN AND ACETYLENE WITHIN THE UNIT, WHICH WILL RESULT IN AN EXPLOSION. IF YOU HAVE QUESTIONS WRITE THEM DOWN AND HAVE THEM ANSWERED BY YOUR INSTRUCTOR. CLICK HERE TO ENTER

  19. STEP 1 BACK-OUT THE OXYGEN REGULATOR SCREW COMPLETELY. THIS IS DONE BY TURING THE SCREW COUNTER-CLOCKWISE. THIS STEP IS NECESSARY TO PREVENT THE HIGH PRESSURE OXYGEN FROM RUPTURING THE REGULATOR.

  20. STEP 2 BACK-OUT THE ACETYLENE REGULATOR SCREW COMPLETELY. THIS IS DONE BY TURING THE SCREW COUNTER-CLOCKWISE. THIS STEP IS NECESSARY TO PREVENT THE HIGH PRESSURE ACETYLENE FROM RUPTURING THE REGULATOR.

  21. STEP 3 SLOWLY OPEN THE OXYGEN CYLINDER VALVE. STAND TO THE SIDE OF THE REGULATOR IN CASE THE REGULATOR RUPTURES. THE VALVE SHOULD BE OPENED ALL THE WAY SO THAT OXYGEN DOESN’T LEAK PASS THE VALVE STEM.

  22. STEP 4 SLOWLY OPEN THE ACETYLENE CYLINDER VALVE. STAND TO THE SIDE OF THE REGULATOR IN CASE THE REGULATOR RUPTURES. THE VALVE SHOULD ONLY BE OPENED ½ TO ¾ OF A TURN. THIS ALLOWS THE OPERATOR TO QUICKLY SHUT THE UNIT DOWN IN CASE OF AN EMERGENCY.

  23. STEP 5 CRACK ( OPEN SLIGHTLY) THE OXYGEN TORCH VALVE.

  24. STEP 6 SLOWLY TURN IN THE OXYGEN REGULATOR SCREW (Clockwise) UNTIL THE DESIRED PRESSURE IS REACHED ON THE WORKING PRESSURE GAUGE. (THE GAUGE ON THE LEFT) FOR TIPS SIZES 000 THROUGH A # 2 THIS SHOULD BE BETWEEN 3-5 psi. PURGE OXYGEN THROUGH THE LINE FOR ABOUT 10 SECONDS.

  25. STEP 7 AFTER PURGING OXYGEN FOR APPROXIMATELY TEN SECONDS, CLOSE THE OXYGEN TORCH TORCH VALVE.

  26. STEP 8 CRACK ( OPEN SLIGHTLY) THE ACETYLENE TORCH VALVE.

  27. STEP 9 SLOWLY TURN IN THE ACETYLENE REGULATOR SCREW (Clockwise) UNTIL THE DESIRED PRESSURE IS REACHED ON THE WORKING PRESSURE GAUGE. (THE GAUGE ON THE LEFT) FOR TIPS SIZES 000 THROUGH A # 2 THIS SHOULD BE BETWEEN 3-5 psi. PURGE ACETYLENE THROUGH THE LINE FOR ABOUT 10 SECONDS.

  28. STEP 10 AFTER PURGING ACETYLENE FOR APPROXIMATELY TEN SECONDS, CLOSE THE ACETYLENE TORCH VALVE TORCH VALVE.

  29. STEP 11 TO LIGHT THE TORCH, CRACK THE ACETYLENE TORCH VALVE AND USE A SPARK LIGHTER TO IGNITE THE TORCH. IF AFTER THREE ATTEMPTS THE TORCH IS NOT BURNING, CLOSE THE ACETYLENE TORCH VALVE, CORRECT THE PROBLEM AND TRY AGAIN (THREE STRIKE RULE). DO NOT LET ACETYLENE GAS BUILD-UP AS AN EXPLOSION WILL RESULT!

  30. STEP 12 AFTER LIGHTING THE TORCH SLOWLY OPEN THE OXYGEN TORCH VALVE UNTIL A NEUTRAL FLAME IS ACHIEVED. THIS IS RECOGNIZED BY A ROUNDED INNER CONE AND THE WELDING TORCH WILL HAVE THE SOUND OF A SOFT “PURR” .

  31. CONGRATULATIONS!! YOU ARE READY TO BURN SOME ROD!

  32. PROPER SHUT-DOWN

  33. TEST YOUR KNOWLEDGE(Click on the correct answer) • The maximum pressure for acetylene is: • 5 P.S.I 10 P.S. I. 15 P.S.I 20 P.S. I 25 P.S.I

  34. WRONG ! YOU ARE AN IDIOT! TRY AGAIN

  35. WRONG ! NOT ONLY ARE YOU AN IDIOT, BUT YOU JUST BLEW UP THE SHOP! TRY AGAIN

  36. CORRECT!!!!!! YOU MAY JUST BE A WELDER AFTER ALL! CONTINUE WITH QUIZ

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