REPUBLIC OF RWANDA

MINISTRY OF EDUCATION

WORKFORCE DEVELOPMENT AUTHORITY

(WDA)
ECOLE TECHNIQUE AUTOMOBILE DE GISENYI
(E.T.A.G)

P.O. BOX: 471 GISENYI

CONTACT: 0788305940
E-mail:etagtech@yahoo.fr

FINAL SCHOOL PROJECT LEVEL A2

suBJect: use of oxy-acetylene gas

welding

OPTION: MOTOR VEHICLE MECHANICS

Prepared by: NZABONIMPA Jean Claude

Tel: 0723620125/0783962995
Email: jeanclaudenzabonimpa88@gmail.com

GUIDE TRAINER: NDAYISHIMIYE Adalbert

Academic Year: 2016

I dedicate my project to:

 Our Almight God,

 My parents,
 My brothers and sisters,
 Our school manager,
 My guide trainer,
 All trainers of E T A G,
 My class mates of E T A G in promotion 2016,
 My greatest friends.

God bless all of them

ACKNOWLEDGEMENT

I great full acknowledge our Almight God who has guide me since my childhood up to now. At
the end of technical secondary school (TSS), a trainee must write a book to get a professional
certificate of level A2.

Let me congratulate the trainers of E T A G for difference skills benefited from them. First, I
would like to thank my guide trainer NDAYISHIMIYE Adalbert for having kindly provided skills
relating to this project. My parents: NSENGIYUMVA Jean Bosco,BUGENIMANA
Bernadetteand my great friends: UWIKIREBERA JEAN BOSCO, NIYIBIZI,
IYAMUREMYE IGNACEand thewhole members of my family who led and advised me during
my school life will no longer is forgotten regarding this achievement.

Yet more, our Gisenyi automotive school manager, for having helped us at school is greatly
recognized. This recognition is finally addressed to my class mates of S6MVM 2016
PURPOSE OF PROJECT

At the end of the secondary studies in motor vehicle mechanics (MVM), each trainee must
write about some particular subject in order to get enough qualification on his subject and get a
diploma of A2 level. That why I present this subject concerning“USEOF OXY-ACETYLENE GAS
WELDING”. This is released to evaluate my school skills. The use of oxy-acetylene gas welding
was very popular so I can deal with this useful activity.

This project of ending technical secondary school “TSS” allows us to an individual research in
relation to more information about gas welding.
DEVELOPMENT OF GAS WELDING

The first successful oxy-acetylene welding equipment was developed in France at the turn of
century (1901-1903). The equipment was introduced to the commercial industries a year later
and it immediately proved successful.

Acetylene was first discovered in 1836 but was not produced successfully on commercial bases
until many years after this when the use of calcium carbide was first discovered.

Gas welding processes are so called because the welding heat is provided by a flame produced
by the combustion of mixture of gases. A variety of gases are used commercially, but an oxy-
acetylene mixture is the most commonly because of its high flame temperature and because
the gases are condiment to handle.

When acetylene and oxygen are mixed in the correct proportion and ignited the resulting flame
reached 3200oc. the welding industry grew very rapidly and by the year 1907 the use of oxy-
acetylene equipment was very popular in all parts of Europe.
CHAP 0: INTRODUCTION

In case of gas welding also known as autogeneous welding, the material is brought to melting
by the heat of a fuel-gas/oxygen flame and joined with the aid of filler metal.

The fuel gas mainly used is acetylene (C2H2) because high flame temperature of approx 32000c
is achieved with acetylene.

There are two systems used in gas welding:

 The high pressure and

 Low pressure system.

The high pressure system uses acetylene supplied in the cylinders.

The low pressure system uses acetylene produced on the promises in an acetylene generator.
As the name “low pressure implies, this acetylene at lower pressure than cylinder acetylene”.

The equipment involves the special safety precaution and a blow pipe that has an injector
system allow the low pressure acetylene to be sucked through by the high pressure oxygen.

High pressure system is the most widely used and therefore the one that you are most likely to
learn welding on. However the next section contains a brief description of low pressure system,
for information.
DEFINITION O F GAS WELDING

A fusion welding process that employs the combustion of fuel gas or gas mixed with oxygen to
provide a high temperature flame capable of melting most metals. Acetylene burning in oxygen
provides an approx 32000c.

A fusion welding is process in which metals are welded together by bringing them to molten
state at the surface to be joined, with or without addition of the filler metal, and without
application of mechanical pressure

 LOW PRESSURE SYSTEM

In the low pressure system, gas is produced by special acetylene generator. The gas is piped
through the hydraulic back pressure valve to the low pressure welding or cutting torch, into
which oxygen is fed from high pressure cylinders. There are two main types of generators:

 Water to carbide.
 Carbide to water.
 HIGH PRESSURE SYSTEM

Acetylene is unstable when under pressure. For storage in cylinder it is therefore dissolved in
chemical called acetone. For this reason it is called dissolved acetylene.

All connecting nuts and fitments on acetylene supply have a left hand thread. They also notches
on them to indicate this.

CHAP I: GAS WELDING

Oxy-acetylene welding is a type of fusion welding. Acetylene and oxygen are mixed in a
chamber, ignited at the tip, and used as high temperature heat source to melt and join the
welding rod and base metal together.

Since it is difficult to concentrate the heat in one area, the heat affects the surrounding areas
and reduces the strength of panels. Because of this problem automakers do not recommend
the use of oxy-acetylene in repairs of damaged vehicles. Although oxy-acetylene is in disfavor
with most automobile manufacturers. With good reason it has some use in body shop. Oxy-
acetylene flame is still used to repair other damaged auto bodies and some heat shrinking
operations and cutting non structural parts.
I.1: GAS WELDING TERMINOLOGY

Parent metal: the material of part to be welded.

Filler metal: metal added to a weld in form of rod, electrode or coil. That part of weld where the
parent metal has been melted, if filler is used and interfusion has taken place this is called the
fusion zone, the depth of which is termed the zone of penetration.

Bordering on fusion zone is the zone of thermal disturbance, consisting of that proportion of
the parent metal which although melted by the flame, has been heated sufficiently to disturb
the grain structure. Where the fusion zone and zone of disturbance meet known as the
junction.

A bead: Is a single longitudinal deposit of weld metal laid on a surface is termed a pad, and is
usually formed by a series of overlapping beads.

Tack welds: are local welds used to holds parts in their correct relative positions read for
welding. Various terms are used to indicate the different part of weld.

Weld face: is exposed face of any weld, a leg is a fusion face of a fillet weld and the toe is a
border line where the weld face adjoins a welded parts, along this line undercut or wastage of
the parent metal in the form of grooving may occur.
The root is the zone at bottom of space provided for occupied by fusion welding and the throat
is the minimum depth of the weld measured along the line passing through the root. The
condition which arises when the filler metal flows on the heated but unfused joint surfaces, and
the interfusion of the filler metals does not take place is known as adhesion.

I.2: GAS WELDING EQUIPMENT

 The high pressure welding equipment comprises:

 Cylinder of dissolved acetylene.
 Cylinder of oxygen.
 High pressure welding torch with separate oxygen control and acetylene control
and various sized tips for different thickness.
 Acetylene regulator with gauges.
 Oxygen regulator with gauges.
 Two 5mm of 10mm high pressure rubber canvas hose with clips and fitted with
hose check valves ( red for acetylene and blue for oxygen.
 Acetylene flash back arrester and oxygen flash back arrester.
 Keys to fit cylinders and spanner for gland nuts, and for fixing the regulators to
the cylinders.
 Pair of goggles.
  Cylinder trolley.

REGULATORS

There are two types of regulators, the two stages and single stage. The oxygen and acetylene
regulators perform two functions:

They reduce the cylinder pressure to the required working pressure and,

They produce a steady flow of gas under varying cylinder pressures.

With the two stage regulator the gas flows from the cylinder into a first chamber where a
predetermined high pressure is maintained by means of spring and diaphragm from the high
pressure chamber. The gas passes the second reducing chamber where pressure is governed by
an adjusting screw.

Both types of regulator have two gauges one indicate the pressure in the cylinder and the
others show the actual working pressure or line pressure at the torch

Figure: reducing regulator

WELDING TORCHES

The welding torch comprises two needles (one for regulating the oxygen and other for the
acetylene). Mixing chamber and an interchangeable welding nozzle, all incorporated in shank.
The torch same times known as blow pipe, mixes acetylenes and oxygen in the correct
proportion and permits the mixture to flow to the end of welding pipe or Nozzle, where is
burned. Blow pipes vary to vary extent design, but basically they are mode to complete control
of flame during the welding operate.

The equal pressure torch is designed to operate when in high pressure system and wall operate
when acetylene is supplied from cylinder.The acetylene and oxygen are fed independently to

the mixing chamber and then flow through the tip

Figure: welding torch

GAS WELDINGHOSES

High pressure gas welding hoses are made with a neoprene lining and over and consist of 3
layers of rubberized canvas and resistance to an abrasion. This eight this makes them eight.
They are color coded blue for oxygen and red for fuel gas. Hose lengths are from 5 to 20 m with
bore diameters of 4.5 mm for maximum working pressure 7 bar and 8 mm for a maximum
pressure 12 bar. Bore diameters of 10 mm are available for a maximum pressure of 15 bars

HOSE CHECK OR HOSE PROTECTORS

Hose check valves are automatic safety devices incorporating a spring loaded non return valve.
The hose c heck valves should be connected between the blowpipe and each hose. The
connection at the blowpipe is by left hand threaded nut for acetylene and right hand threaded
for oxygen supply.

Although the check valves will prevent a back fire from the damaging the hoses, and reduce the
risk of flash back, they will not actually stop a flash back for full protection against the danger of
flash back, arrester must be fitted.

FLAME TRAPS (FLASH BACK ARRESER)

In gas welding and gas cutting equipment, flame traps protect the operators and equipment
against the hazard of mixed gas explosion. They should carry full health and spectorage
approval for operation with the recommended working pressure specified for each model.

I.3: TYPES OF FLAME AND ADJUSTMENT

When the acetylene and oxygen are mixed and burned in the air, the condition of flame varies
depending on the volume of oxygen and acetylene.

There are three types of flame:

 Neutral flame: the standard flame is said to be neutral flame. Acetylene and oxygen
mixed in 1 to 1 ratio by volume produces a neutral flame. This has brilliant cone
surrounded by clear blue outer flame.

 Carburizing flame: the carburizing flame, also called a surplus or reduction flame. This
obtained by mixing slightly more acetylene than oxygen. This flame shows that differ
from the neutral flame is that it has three parts. The cone and the outer flame are the
same as the neutral flame, but between them there is an intermediate light cored
acetylene cone enveloping the cone. The length of the acetylene cone varies according
to the amount of surplus acetylene in the gas mixture. For a double surplus flame, the
oxygen acetylene mixing ratio is about 1 to 1.4 by volume. A carburizing flame is used
 for welding Aluminium nickel and other alloys.

 Oxidizing flame:the oxidizing flame is obtained by mixing slightly more oxygen than
acetylene. The oxidizing flame assembles the neutral flame in appearance, but the
acetylene cone is shorter and its color is a little a violet compared to the neutral flame.

The outer flame is shorter and fuzzy at the end. Originally, this flame oxidizes melted metal, so
it is not used in the welding mild steel, but it is used in the welding of brass and bronze.

TEMPERATURE OF THE FLAME

When the acetylene burned with an equal volume of oxygen, a maximum flame temperature of
32500c about 2.5 times hotter than the melting point of cast iron and steel. Variation of the
proportion of the oxygen and acetylene can be made at the welding torch
Figure: temperature of flame

I.4: THE GAS ECONOMISER

The gas economizer is a very useful item of equipment designed for use with pipe line
distribution of oxygen and acetylene welding point. It contains two valves, which are normally
held open by spring but will be closed by the weight of a blowpipe hung or the control lever
arm.

Oxygen and acetylene supplies coupled to the inlet side of the sitting, and the gas hoses to the
blowpipe is lifted off the arm, the gases can be ignited at the pilot light and the flame can be
adjusted to the correct setting in the normal way between welding operations, the blowpipe is
hung on the arm shutting off the gases.

Without the use of the gas economizers, a lot of gas can be wasted while the flame is being
adjusted and while the blowpipe is laid aside with the flame burning when a job is being
changed or adjusted. Installing gas economizers can reduce the gas consumption by as much as
20 percent.

I.5: THE FLAME ABNOMALITES

When changes occur during gas welding, such as overheating of flame outlet, adhesion of
spatter, or fluctuations in the gas adjustment pressure, the result will be variation in the flame
in the weld.
Therefore, you must always be aware of the condition of the flame.

S Y M P T O M C A U S E S R E M E D Y
Flame fluctuations Moisture in the gas, condensation in hose. Remove the moisture from the hose.
Insufficient acetylene supply. Adjust the acetylene pressure and have the tank r
Explosive sound while lighting the torch. Oxygen or acetylene pressure is incorrect. A d j u s t t h e p r e s s u r e .
Removal of mixed in gases are incomplete Remove the air from inside the torch.
The tip orifice Is too enlarged. Replace the tip
The tip orifice is dirty. Clean the orifice in the tip.
F l a m e c u t o f f . Oxygen pressure is too high. Adjust the oxygen pressure.
The flame outlet is clogged. Clean the tip.
Popping noises during operation. T h e t i p i s o v e r h e a t e d . Cool the flame outlet (white letting little oxygen flow).
The tip is clogged. Clean the tip.
The gas pressure adjustment is incorrect. Adjust the pressure.
Metal deposited on the tip. Clean the tip.
Reversed oxygen flow (oxygen is flowing to the path of acetylene). T h e t i p c l o g g e d . C l e a n t h e t i p .
The oxygen pressure is too high. Adjust the oxygen pressure.
The torch is defective (the tip or valve Repair
is loose).
or replace the torch.
There is a contact with tip and the depositClean themetal.
orifice.
B a c k f i r e . Low acetylene following in the torch. A d j u s t t h e f l o w r a t e .
Oxygen pressure is too low. Adjust the oxygen pressure.
The tip orifice is enlarged. Replace the tip.
The tip overheated. Cool the tip with water (letting oxygen flow).

CHAP II. HIGH PRESSUREAND LOW PRESSURE BLOWPIPES FORWELDING AND CUTTING.

II.1. THE HIGH PRESSURE BLOW PIPES

The high pressure blowpipe is simply a mixing chamber, with regulating valves to vary the
pressure of the gases as required. The oxygen and acetylene enter the blowpipe through
separate connections and then mix in the gas mixer, arriving at the nozzle in approximately
equal volumes.

Figure principle of the high pressure blowpipe

A selection of nozzles is supplied with the blowpipe. These have openings of varying sizes and
each is stamped with a number, usuall6y indicating the consumption of gas in cubic fit or liters
per hour depending on the made.

These nozzles will cover a range of welding requirements from thin sheet to the heavy duty
welding. The high pressure welding blowpipe must not be used on low pressure system.

II.2. LOW PRESSURE BLOWPIPE

The low pressure blowpipe contains an injector system. High-pressure oxygen travels through
the injector and draws the low pressure acetylene into the mixing chamber, giving its sufficient
velocity to maintain a steady flame. Fig principle of low pressure blowpipe

The injector will also help to prevent back firing. It is usual for the whole head to be
interchangeable with this type of blowpipe, as the head contains both the nozzle and the
injector, and the injector size will vary for each nozzle size.

The low pressure welding blowpipe is more expensive than the high pressure type. It can be
used on the high pressure system, but its uses have fallen over the last few years compared
with the high pressure blowpipe and high pressure system.

The low pressure system is no longer widely used, and not at all body repair work.

II.3. LIGHTING BLOWPIPE

To light the blowpipe, set the regulator to the recommended pressures. Do this under the
supervision of a skilled welder, until you have got the procedure perfected. When the
regulators are set correctly, turn on the acetylene valve on the blowpipe and light the acetylene
at the nozzle with the spark lighter.

Do not use a match. At the first flame will be yellow and smoky. The soot and smoke being
given off are carbon as combustion is incomplete because the shortage of oxygen in the flame.
Use oxy-acetylene valve on the blowpipe to increase and decrease the yellow flame until the
black smoke reduce and disappear the acetylene supply is now right for the particular size of
nozzle you are using.

II.4. HEAT CRAYONS

With steel, the use of heat avoided whenever possible to prevent reducing the strength of the
metal. With Aluminium, the heat must be used to restore flexibility caused by work hardening.
If not it will crack when straightening force is applied.
Heat crayon or thermal paint can be used to determine the temperature of Aluminium or other
metals being heated. They will melt as a specific temperature warns you to prevent
overheating.

II.5. CLEANING WITH TORCH

It is important before starting any weld that the surfaces to be joined must be thoroughly clean.
The weld site must be completely free of any foreign material that might contaminate the weld.
The finished weld is quite likely to be brittle, porous and of poor integrity.

To remove heavy under coating rust, proofing, tars, caulking, sealants, road dirty and primers,
first use a scraper to get off the loose material. Then use a scraper and an oxy-acetylene torch,
using the carburizing flame. In any event, keep the torch at every low, controlled heat to
prevent the part damage. Use just enough heat to keep the work done.

CHAP III. USING A GAS WELDING EQUIPMENT

When you assembling equipment never use oil or grease as these substances can ignite causing
an explosion, soapy water ca easy thread and will also indicate if there is a leak. Any
connections that not assemble easily need to be replaced, but remember that acetylene
fitments have left hand threads and oxygen fitments have right hand threads.

Before opening the cylinder valves check:

 Hoses for burns or cut that may leak,

 All connections for tightness,
 That the regulator pressure valve is off (loose).
 That both blow pipe valves are closed.

The cylinder valves should be opened just half turn using the valve spindle key.

 Check that the cylinder valves is shut off

 Check that the hoses have been emptied of oxygen and acetylene, by opening
the blowpipe valves until the welding pressure gauge indicate zero and then
closing both blowpipe valves
 Turn off the regulator valve (loosen the pressure adjusting screw).

III. 1. LEFT WARD TECHNIQUE OF AS WELDING

There is a technique or method of welding in which the welding torch flame is directed toward
the uncompleted joint. The advantages of the left ward technique are that: it is faster because
the flame, in preceding the weld, has preheating, and penetration (complete fusion of the
edges).
The characteristics of the leftward welding technique are as follow:

 Position-flat
 Direction of welding- flame points towards finished weld.
 Angle of welding torch-straight along seam; with sufficient side swing to ensure
complete of the edges.
 Gas consumption of the welding torch-140l/h which is 3ft3/h for 1.6mm
thickness.
 Position of a filler rod-welding torch.
 Types of flame: neutral.
 Angle of the filler rod-40%-50%
 Movement of filler rod- slight movement in and out of molten spool.
 Size of filler rod half the plate thickness up to the maximum 6.4mm

Figure: left ward technique of gas welding

II.2.NOZZLE SIZES AND GAS PRESSURE

As the thickness of the work increases the flame will be required to supply more heat. This is
made possible by increasing the nozzle size and regulator as pressures in accordance with
manufacture instruction.

If you try to weld thick metal with a small nozzle by increasing gas pressure there comes a point
indicates that the pressure is too high resulting in very noisy flame. It is much better to work
with a ‘soft’ flame which is obtained by using correct nozzle size and pressure settings.

At other extreme, if you try to weld with a too large for the work by reducing the supply of gas
at the below pipe valves instead of charging to a smaller nozzle then small explosions will occur
at the nozzle. These small explosions indicate that the gas pressure is too low.

III. 3. RIGHT WARD TECHNIQUE GAS WELDING

These days it is more usual 2 used one of they are welding processes on materials above 4 mm
thickness, but the right ward method is hand to know. Some welding courses include it, and
belief description is given here.

Some advantages of this method on thicker plate are follows:

It is faster and uses less filler rod, so it is less expensive

There is less expansion and therefore less contraction

The flame remains over the deposition metal, giving annealing action

A better view of the molten pool is obtained, allowing for greater control of the welding
operation.

III.4. WELDING RODS AND FLUXES

FILLER RODS

Filler rods for use in oxyacetylene welding are available in the following metals: mild steel,
wrought irons, high carbon steel, alloy steel, stainless steel, and cast iron steel, copper alloy,
aluminum alloys, hand facing alloy, zinc based die-cast alloys.

The metal from the rod has considerable influence in quality of finished weld. Good welding rod
are designed to give deposited metal of the correct composition and have allowance in their
chemistry for changes which take place in welding processes.
Rods are obtained in size ranging from 1.6mm to 5.0mm diameter. Sounds welds comparable in
strength with the metal welded, can be produced with satisfactory filler rods.

WELDING FLUXES

It is impracticable to incorporate in welding rods all the elements necessary to overcome

oxidation, therefore it is necessary to us with them certain chemical compounds to act as
deoxidizing agents or fluxes, which must be of correct composition to ensure perfect welds .A
flux must be used with the following metal: cast iron, high carbon steel, stainless steel, copper,
copper alloys, aluminium, aluminium alloys, magnesium alloys. In the majority of cases it is
essential the flux residues should be removed from the surface of metal after the welding
operation has been completed.

CHAP IV. GAS CUTTING

The oxy-acetylene process is widely used to cut metal, especially in the body building industry
where heavy sections have to be cut to especially shapes for construction and also in the repair
side of the industry where special nozzles have been developed for cutting away damaged parts
of sheet metal body sections. Cutting may be done by means of a simple hand cutting torch, or
by a more complicated, automatically controlled cutting machine.

IV.1. GAS CUTTING EQUIPMENT

In general, an oxyacetylene welding and cutting out fit consist of the following:

1. Steel tanks (cylinders) filled with;

 Oxygen
 Acetylene
2. Regulators, which reduce the pressure coming from the tanks to the desired level and
maintain a constant flow rate of oxygen pressure (103 to 689 kpa)15-100psi acetylene
pressure 3 TO 12 PSI
(21to 83Kpa).

3. Hoses from the regulators and cylinder connect the oxygen and acetylene to the torch.

4. Torch. The torch body mixes the oxygen and the acetylene from the tanks in the proper
proportion and produces a heating flame cable of the melting steel.
 Figure: cutting torch

IV.2. GAS CUTTING TORCH FLAME ADJUSTMENT

The cutting torch is sometimes used in collision repair shop to rough cut damaged panels. Gas
cutting torch flame adjustment and cutting procedures are as follows:

Adjust the oxygen and acetylene valves for a preheating neutral flame.

Open the preheating oxygen valve slowly until an oxidizing flame appears. This makes difficult
for molted metal to remain on the surface of, allowing for clean edges.

Thick panel cutting method: Heat a portion of the base metal until it is red hot just before
(melt) open the high-pressure oxygen valve and cut the panel advance the torch forward while
making sure the panel is melting and being cut apart.

This method is widely used for thick panels when there are several pieces overlapped together
or for a side member even when there is an reinforcement.

Thin panel cutting method: Heat a small spots on the base metal until it is red hot. Just before
it melts open the high pressure oxygen valve and incline the tip torch to cut the panel. When
cutting thin material inclines the tip of torch so that the cut will be clean and fast (this prevents
a wanted panel war page).
SHOP TALK
As soon as the cutting operation is completed, quickly turn off the high pressure oxygen flow
used for cutting and pull the torch away from the base metal. This action prevents sparks from
entering the tip and igniting the oxygen-acetylene mixture in the torch handle. In extreme cases
the ensuring fire could melt the torch handle.

IV. 3. CUTTING TORCHES AND NOZZLES

CUTTING TORCH

This differs from the regular welding torch in that it has an additional lever for the control of
the oxygen used to burn the metal. It is possible to convert a welding torch into a cutting
attachment.

The torch has conventional oxygen and acetylene valves and these are used to control the
passage of oxygen and acetylene when heating the metal. The cutting tip has an orifice in the
centre for the oxygen flow, surrounded by several smaller holes for preheating flame which
generally uses acetylene, propane or hydrogen.

The preheating flame has two purposes:

To provide sufficient heat, raise a small area of the steel surface to the ignition temperature,
transmits sufficient heat to the top surface of the steel and offsets the normal conductivity of
metal.Alternatively, oxygen enters the torch at very much high pressure than the fuel gas and
sucks the fuel gas in through an injector which also mixes the two gases. These are termed
injector cutting torches. Both designs are equally good for flame cutting.
Figure: cutting torch

NOZZLES

A number of different designs of nozzles are available to swat various combinations of fuel
gases and torch design. In principle, however, nozzles are the same. They have central orifice
for cutting oxygen stream, surrounded by a ring of orifices for preheat flame.

A typical oxy acetylene nozzle has circular preheat holes surrounding a central circular cutting
oxygen orifice, and is frequently of a one piece construction made of copper and often chrome
plated.

IV.4. GENERAL GAS STORAGE PROCEDURES

1. Any person in charge of storage of compressed gas cylinders should know the
regulations covering highly flammable liquids and compressed gas cylinders as well as
the characteristics and hazards associated with individual gases.
2. It is best to store full or empty compressed gas cylinders in the open, in a securely
fenced compound, but with some weather protection.
 3. Within the storage area oxygen should be stored at least 3m from fuel gas supply
4. Full cylinders should be stored separately from the empties, and cylinders of different
gases, whether full or empty, should be segregated from each other.
5. Other products must not be stored in a gas store, particularly oils or corrosive liquids
6. It is best to store all cylinders up right, taking steps, particularly with round bottomed
cylinders, to see that they are secured to prevent them from falling. Acetylene and
propane must never be stacked horizontally in storage or in use.
7. Storage arrangements should ensure adequate rotation of stock.

A CETYLENE CYLINDER

1. The gas is stored together with solvent (acetone) in maroon pointed cylinders, at a
pressure of 17.7 bar maximum at 150c. The cylinder valve outlet is screwed left
handed.
2. The hourly rate of with drawl from the cylinder must not exceed 20 percent of its
content.
3. Pressure gauges should be calibrated up to 40.0 bars.
4. As the gas is highly flammable, all joints must be checked for leaks using soapy water.
5. Acetylene cylinders must be stored and used inan cup right position and protected
from excessive heat and coldness.
6. Acetylenecan form explosive compounds in contact with certain metals and alloys,
especially those of copper and silver. Joint fitting made of copper should notbe used
under any circumstances.
7. The color of cylinders, valve threads; makings must not be altered or tampered within
anyway.

OXYGEN CYLINDERS

1. This gas is stored in black painted cylinders at pressure of 200/230 bar maximum at
15oC
2. Never under any circumstances allow oil greases to come into contact with oxygen
fittings because spontaneous ignition may take place.
3. Oxygen must not be used in place of compressed air.
4. Oxygen escaping from a leaking hose will form an explosive mixture with oil or
grease.
5. Do not allow cylinders to come into contact with electricity.
6. Do not use cylinders as rollers or support.
 7. Cylinder must not be handled roughly, knocked or allowed to fall to the ground.

IV.5. GENERAL EQUIPMENT SAFETY

All equipment should be subjected to regular periodic examination and overhaul. Failure to do
so may allow equipment to be used in a faulty state, and may be dangerous.

1. Rubber hose: use only hose in good condition, fitted with the special hose connection
attached by permanent ferrules. Do not expose the hose to heat, traffic, slag, sparks
from welding operations, or oil or grease. Renew the hose as soon as it shows any sign
of damage.
2. Pressure regulators: always treat a regulator carefully. Don’t expose it to knocks, jars, or
sudden pressure caused by rapid opening of the cylinder valve. When shutting down,
release the pressure on the control spring after the pressure in the hose has been
released. Never use a regulator on any gas except that for which it was designed, or for
high working pressures. Do not use a regulator with broken gauges.
3. Welding torch: when lighting up and extinguishing the welding torch, the manufactures
instruction should always be followed. To clean the nozzle use special nozzle cleaner,
never use a steel wire.
4. Fluxes: always use welding fluxes in well-ventilated areas.
5. Goggles: these should be worn at all times during welding, cutting or merely observing.

GLOBAL SKETCH

`
CONCLUSION

Today this type of welding is no longer used in the construction but only in the repair of motor
vehicles.

A casual inspection of modern car reveals little evidence of welding, yet no modern car could
be assembled without it.

In body repair work welding techniques are used for frame straightening, reinforcing frame
members and welding in new or patching old panel assemblies.

At one time this type of repair was affected by either riveting a patch over the rusted or torn
parts, or renewing the part concerned.

With the development of small portable gas welding equipment, however, the edges of the
material can be heated locally until they melt, and then fused or welded together.

BIBLIOGRAPHY

 MODERN TECHNOLOGY
 PRACTICAL WELDING (MOTIVATE)
 VEHICLE BODY REPAIR
 RESEARCH ON INTERNET
PART LIST

1. tip
2. Cutting torch
3. Acetylene hose connection
4. Oxygen hose connection
5. Working pressure gauge
6. Oxygen regulator
7. Oxygen hose
8. Twin hose
9. Oxygen cylinder
10. Cylinder pressure gauge
11. Acetylene valve wrench
12. Acetylene regulator
13. Acetylene hose
14. Acetylene cylinder