Oxy-Acetylene Welding

Oxy-Acetylene Welding is the welding process of heating two pieces of metal to melting point, bringing the parts together and while still in a molten stage hammered together to form a joint. Learning how to weld using this process will give a complete overview of welding.

The Oxy-Acetylene Welding process requires the use of a special welding torch that mixes oxygen and acetylene gasses that can produce a small intense flame heat of up to 6300 degrees. This temperature is more than twice the melting point of most metals.

This process has been widely used in the past for the manufacture of wrought iron projects such as iron gates and fences. These methods have widely been superseded by the introduction of electric arc welding.

Today Oxy acetylene welding is generally restricted to industries that work with copper pipe and the joining of copper and brass. Other specialized applications include such as building up of brass wear plates and the welding of cast iron housings that may be cracked using brass or bronze rods as a filler.

Gas Cutting Using Oxy-Acetylene.

Most gas torches include a function for gas cutting. This is in the form of a lever style valve that allows an extra burst of oxygen through the cutting torch to the work that has been heated to melting point.
This injection of oxygen to the work causes the parent metal to burn away with great force and speed, producing a small narrow cut in the metal.

Using this method has allowed metals to be cut easily either manually or by machines called profile cutters. Gas cutting manually can easily cut metals of 1/16 of an inch and up to two inches where as profile cutting can cut steels up to four inches thick.

Many profile cutting machines now use LPG gas instead of acetylene as the flame and cut produced is cleaner. Propane torches for auto and manual cutting are constructed differently to acetylene torches and also require different cutting tips

Welding Rods

When choosing welding rods try to avoid buying inferior quality as the better your grade of material in the welding rod the better the end result will be.

Your welding rod is used to lay over additional metal to the weld therefore it needs to match the parent metal. If the metals are dissimilar then best efforts to locate a filler rod comprising of a composition of the two metals. For example if welding manganese, or nickel specific welding rods of specific alloys are recommended.

Welding wire and Oxy-Acetylene Welding rods are most always of Norway steel. This grade is most pure and gives a sound soft weld especially suited to machining if required. When welding aluminium the proper rod is most important as aluminium is difficult to weld and requires alloyed rods to ensure even flowing.

Brazing Metals – The Basics

brazing metalsBrazing metals is the method for joining up steel with the aid of a filler metal which is heated up in the top surface area and it is dispersed among several components which are carefully fixed together by way of capillary activity. Taking this filler metal to the temperatures that’s a touch greater than it’s melting stage and also safeguarding it that has an atmosphere that’s ideal is known as flux. This kind of heated filler metal will then be permitted to pass across the base metal to help fusion with the welded components.

Brazing can be used to the various possibilities it supports. For example, you can use it as manually operated torch brazing when the torch will be hand-held to make a excellent joint involving the materials it’s applied to. In contrast producers can make use of machines torch brazing if they require recurring brazing carried out while not having to tie up any specific welder for extended amounts of time. Then there’s the automated torch brazing technique that totally removes the requirement of utilizing manual labour with the brazing procedure.

Silver brazing utilizes filler based on the silver material comprising materials for example gold, zinc, copper, as well as cadmium. This technique can be used in most cases within the tool community in which tips of tools tend to be attached using hard-metal. This is particularly helpful if utilized in those tools as saw blades.

Braze welding implementes brass as well as bronze filler rods which are covered by flux whenever joining work items made from metal. The apparatus employed for this kind of welding is similar for that found in brazing. Because the requirement of this kind of welding is made for greater temperature, acetylene or methylacetylene-propadiene gas MPS) is frequently utilized to achieve this. This system is especially appealing to a few since the metal isn’t melted throughout the procedure and for that reason every part maintain their particular edges, forms, and curves without getting altered or eroded.

Cast iron brazing employs nickel or cast iron rods whenever accessible and it is frequently utilized to inbed copper wire in to tube in order to conduct energy to avoid freezing in the course of inclement weather conditions. Vacuum brazing metals is yet another approach to welding that’s really clean, good quality and helps to create flux-free joints which are robust and still have remarkable integrity.

Dip brazing is actually suited with regard to brazing aluminium simply because that oxygen is not really utilised that helps prevent oxides by developing. Within this kind, the various components tend to be put together and a brazing is usually applied in a slurry, then this complete product will be dropped in to a molten sodium bath that works as a heat transfer channel plus flux.

Furnace brazing metals is yet another approach that’s frequently utilized but it’s only semi-automatic in kind, however frequently employed within manufacturing environments. There are a variety of advantages for making use of this technique particularly when dealing with mass manufacture of products. It is especially good for working by using great amounts of smaller sized components that may be jigged very easily.

 


Learning How To Tig Weld

Once you learn how to tig weld you will be considered a serious welder and for many an artist. Tig welding really is an art form. Most people will not see this however creating the perfect bead of weld in the place you want it does require skill and creativity.

how to tig weldThe Tig welding process can be used to weld many metals, brass, aluminium, steel, copper, bronze, nickel alloys and gold.

Tig welding or tungsten inert gas welding begins using a tungsten electrode that once struck creates an arc to heat and fuse metals to be welded. The tungsten electrode does not actually touch the work but is held at a distance from the work that is enough to create heat and, with the aid of a filler electrode, fusion occurs.

To eliminate the need for flux a shielding gas is used in a similar manner to mig welding and is delivered via  the tig torch itself. The gas, generally pure Argon, protects the weld from outside contamination.

Setting up the Tig welding machine is a key component to learn how to tig weld and can be summarized as;

–          Set up gas supply to tig torch

–          – Set up welding inverter power. This all depends on the type and thickness of the metal / alloy to be welded. This should be available in the welding machine manual.

–          Attach earth clamp.

–          Grind tungsten electrode to a point, the grinding is important, grind the point along the length of the electrode and not around it, the length of the grind should be two and a half times the diameter of the electrode, grind a small flat at the tip, not a sharp point. Grinding in this manner will prevent any welding ‘wander’.

–          To start welding the torch needs to be held at between 70 to 80 degrees. Keep the tip about 1/8 to ¼ inch from the work being welded. Practice controlling the arc ‘puddle’ width at approx ¼ inch wide.

–          Next add filler rod to the weld in small blobs or dabs, always try to keep the torch at a constant distance from the work and a smooth weld speed. Push the weld rather than pull.

Once you learn how to tig weld it is a most satisfying accomplishment. Tig welding is a very clean process and requires little or no clean-up. This makes it ideal for welds that are highly visible in a decorative situation such as furniture, stainless steel or aluminium components and art work.