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Oxy-acetylene welding is one type of welding process used in metal fabrication. This type of welding uses a torch fed by an oxygen and acetylene fuel mixture to heat the metal parts to be welded as well as the welding filler rod used to add material to the weld. Oxy-acetylene welding has been in use since the turn of the 20th century, and does not require electrical power, allowing the welding equipment to be used in a wide variety of environments.

Oxy-Acetylene Welding Equipment

A welder using the oxy-acetylene welding process will use the following equipment:
Oxygen cylinder with pressure regulator
Acetylene cylinder with pressure regulator
Torch
Hoses to connect cylinders to the torch
Safety clothing and equipment

Different torches are available for welding as opposed to cutting. In both cases, the hoses are designed with valves to prevent back flow of the oxygen-acetylene mixture into the tanks as well as preventing shock waves from traveling back to the tanks.

Oxy-acetylene Welding Process

The welder begins the welding operation by creating a flame on the torch. The valves on the gas cylinders and the torch are opened. The welder ignites the gas exiting the torch with a sparker or lighter. Then, the welder adjusts the oxygen-acetylene mixture to achieve a neutral, two zone flame. The neutral flame consists of two blue zones, a lighter inner zone and a darker outer zone. Too much acetylene results in a carbonizing flame, too much oxygen results in an oxidizing flame.

The welder then uses the flame to create a small pool of metal at the weld zone, and then moves the torch to move the pool of metal. If additional metal is needed to fill a weld, a welding rod is inserted into the pool of metal, where it melts and adds to the weld. The welder progresses linearly along the weld at a constant rate to create an even bead.

Welding Safety

Gas welding is an inherently dangerous activity and several precautions must be taken to preserve the safety of the welder and the environment. The welder must don several items of protective clothing, including gloves and an apron of flame resistant material, usually leather. The welder must also wear a welding helmet. The helmet serves two purposes: to protect the face and neck from sparks and to protect the eyes from the intense light produced by the flame at the weld location.

Welders must also handle their welding equipment with care. Gas cylinders must be secured into wall-mounted brackets or portable carts specifically designed for welding equipment. Ventilation is required during the welding process to prevent the buildup of harmful gases around the welder, such as carbon monoxide.

Oxy-acetylene welding is a widely used fabrication process that has been used for over a century to produce high-quality welds and structures.