Post on 02-Jun-2018
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OXY-FUEL GAS CUTTING
DEFINITON : A group of cutting processes used to several metals
by means of the chemical reaction of oxygen with the
metal at elevated temperature. The necessarytemperature is maintained by mean of gas flamesobtained from the combustion of specified fuel gasand oxygen
( OFC-A; OFC-H; OFC-N; OFC-P)
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OXY-FUEL GAS WELDING andBRAZING
WELDINGMaterial joining process used in making weldWeld : A localized coalescence of metals or nonmetalsproduced either by heating the materials to suitabletemperatures, with or without the application of pressure , or bythe application of pressure alone and with or without the use offiller materialOxy-fuel gas welding ( OFW ): A group of welding processwhich produces coalescence by heating materials with an oxyfuel gas flame or flames, with or without the application ofpressure and with or without the use of filler metal
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OXY-FUEL GAS WELDING AND
BRAZING
FUSION WELDING : Any welding process or method which uses fusion to complete the
weld.
Fusion : The melting together of filler metal and base metal (substrate ), or base metal only, which result in coalescence. Depth of fusion : The distance that fusion extends into the base
metal or previous pass from the surface melted during welding
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OXY-FUEL GAS WELDING AND
BRAZING TORCH BRAZING (TB) :
A brazing process in which the heat required is furnished by afuel gas flame.
TORCH SOLDERING (TS) : A soldering process in which the heat required is furnished by afuel gas flame.
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OXY-FUEL GAS PROCESSES
1. PRINCIPLES OF PROCESS
2. GASES
3. EQUIPMENTS
4. WELDING PROCEDURE AND TECHNIQUES
5. SAFETY
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PRINCIPLES OF PROCESSES
DEFINITION The process involves melting the base metal and usually a filler
metal,using a flame produced at the tip of welding torch. Fuelgas and oxygen are combined in the proper proportions in sidea mixing chamber which may e part of the welding tipassembly. Molten metal from the plate edges, and filler metal, ifused, intermix in a common molten pool and coalesce uponcooling.
Flame Temperature of a fuel gas will vary according to the
oxygen-to-fuel ratio. Combustion Intensity takes into account the burning velocity
of the flame, the heating value of the mixture of oxygen andfuel gas, and the area of the flame cone issuing from the tip.
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GASES( 1.02 6 )
OXYGEN Manufacture of oxygen Properties Storage of oxygen Pressure and temperature Content of oxygen Oxygen consumption Unloading volume of oxygen
FUEL GASES Type of fuel gases Requirements of fuel gases Explosion limits Permissible gas consumption rate Summary of fuel gases
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GASES
ACETYLENE Manufacture Storage of acetylene Content os an acetylene cilinder
PROPANE GAS What is propane gas Special handling and safety Others
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EQUIPMENTS
1. GAS CYLINDERS 2. CYLINDERS VALVES 3. CYLINDER PRESSURE REGULATORS
4. SAFETY EQUIPMENTS 5. WELDING HOSES 6. WELDING TORCH
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EQUIPMENTS
GAS CYLINDERS Color-code and cylinder connections Transportation ( handling ) of gas cylinders Storage of gas cylinders
CYLINDER VALVES Standards
CYLINDER PRESSURE REGULATORS Function Operating instruction Leak test of a pressure connection Gauges
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EQUIPMENTS
TORCHS Design of torch Correct blowpipe attacment Injector blowpipe Special attachment Maintenance and services
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WELDING PROCEDURE AND
TECHNIQUE OXY-ACETYLENE FLAME
Combustion of the oxy-acetylene flame Type of welding flame Flame intensity Flame distance Backfire Reverse flow (backflow) Flashback Remedies
INITIATION OF THE GAS WELDING PLANT Igniting and regulating the welding flame Extinguishing the flame
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WELDING PROCEDUR AND
TECKNIQUE DISCONTINUITIES ( DEFECTS )
Shapes /Visual Inspection Destructive Test NDT
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THE OTHER APPLICATIONS OFOXY-FUEL GAS PROCESSES
OTHER APPLICATION
SURFACING/SPRAYING
BUILDING UP WELDING
HARD FACING
ACID RESIST. FACING
BRONZE FACING
APPLICATION
COATING/CLADDING
CLEANING
HEATING
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THE OTHER APPLICATION . . . . .
APPLICATION
HEATING
Flame Straightening
Stress Relieving
Flame hardening
Tempering
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B1.13CUTTING AND OTHER EDGE
PREPARATION PROCESSES (1 ) EDGE PREPARATION METHODS
EDGE PREPARATION
THERMAL CUTTING
LASER CUTTING
OXY- FUEL GAS CUTTING
ARC CUTTING
OTHERS
AIR CARBON ARC CUT.
PLAZMA ARC CUTTING
OXYGEN ARCCUTTING
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CUTTING AND OTHER EDGE
PREPARATIONS PROCESSES(2)
PREPARATION METHODS
MECHANICAL C.
SAWING
SHEARING
GRINDING
PLANING
MILLING
WATER JET CUTTING
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THERMAL CUTTING
CLASSIFICATION AND SELECTION OF METHOD( 1.14-5 )
APPLICATIONS OF THERMQAL CUTTING( 1.14 6 )
COMPREHENSIONS FOR CUTTING( 1.14 7 )
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OXY-FUEL GAS CUTTING (1)( 1.14 8-26 )
FONDAMENTALS OF THE PROCESS ( ADD. ) PROCEDURE OF CUTTING (1.14 8-10)
SUITABILITY OF MATERIALS ( 1.14
10-12 ) CUTABILITY OF STEEL ALLOY (1.14 12-13 ) EQUIPMENTS ( 1.14 13-18 ) HARDENING OF THE CUT SURFACE ( 1.14 - 18 ) QUALITY OF THE CUT SURFACE ( 1.14 19-21 ) FAULTS IN THE CUTS AND THEIR CAUSES ( 1.14
21-26 )
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OXY-FUEL GAS CUTTING (2)
FONDAMENTALS OF THE PROCESS ( ADD. ) DEFINITION:
OFC is a group of cutting processes used to sever metals bymean of the chemical reaction of oxygen with the base metalat elevated temperatures. The necessary temperature ismaintained by mean of gas flames obtained from thecombustion of a specified fuel gas and oxygen.
PRINCIPLES OF OPERATION: OFC begins by heating a small area in the surface of the metal
to the ignition temperature with an oxy-fuel gas flame. Acutting oxygen streams then directed at the preheated spot ,causing rapid oxidation of the heated metal and generatinglarge heat. This heat supports continued oxidation of themetal as the cut progresses.
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OXY-FUEL GAS CUTTING (3)
PROCEDURE OF CUTTING STARTING AT THE EDGE OF PALATE PIERCING
SUITABILITY OF MATERIALS FOR OFC The ignition temperature for the burning of the metal at the cut
must be lower than its melting temperature of the parent metal. Melting temperature of the oxide layer (slag) must be lower than
the melting temperature of the parent metal. The burning slag must be of low viscosity. He thermal conductivity of the material must be low. Materials must have good cut-ability.
CUTTABILITY OF ALLOYS STEEL
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OXY-FUEL GAS CUTTING (4)
PMENTSTTING ATTACHMENTS
AME CUTTER NOZLES
ENING OF THE CUTT SURFACEITY OF THE CUT SURFACE
DGED BYPENDING UPON
Cutter nozzle
Intensity of flamePurity of cutting oxygenFlame adjustmentType of flameManipulation of blowpipeMaterial
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OXY-FUEL GAS CUTTING (5)
FAULS IN CUTTING AND THEIR CAUSES Nozzle too close Cutting speed too low Heating flame too large Nozzle too far from the plate Faulted nozzle Cutting speed too high
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B 1.16
SOLDERING AND BRAZING DEFINITION ADVANTAGES
CLASSIFICATION WORKING PROCEDURE HEATING TIME AND SOLDERING
TEMPERATURE
FLUXES SOLDERS APPLICATION
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SOLDERING AND BRAZING
DEFINITION (1) Soldering (S): A group of welding processes which
produces coalescence of materials by heating themto a suitable temperature and by using a filler metalhaving a liquidus not exceeding 840 0 F and below ofthe solidus of the base metal. The filler metal isdistributed between the closely fitted faying
surfaces of the joint by capillary action. Brazing (B) : A group of . . . . . . Above 840 0 F
and below of . . . . . . . . . . . . . ..
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SOLDEERING AND BRAZING
DEFINITION (2) Braze welding : A welding process variation in which a
filler metal, having a liquidus above 840 0 F and below aliquidus of the base metal is used. Unlike brazing , inbraze welding the filler metal is not distributed in the
joint by capillary action. Solder : A filler metal used in soldering which has a liquidus
not exceeding 8400 F.
Brazing filler metal : The metal which fills the capillary gap anghas a liquidus above 840 0 but below the solidus of the base metal.
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SOLDERING AND BRAZING
DEFINITION (3)
Brazer : One who performs a manual or semiautomaticbrazing operation. Brazement : An assembly whose component part are joinned by
brazing. Brazing operator : One who operates machine or automatic
brazing equipment. Brazeability : The capacity of metal to be brazed under the
fabrication conditions imposed into a specific suitably designstructure and to perform satisfactorily in the intended service.
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SOLDERING AND BRAZING
CLASSIFICATION (1) WORKING TEMPERATURE
Soft soldering (below 450 0 C ) Hard soldering / brazing ( 450 0 900 0 C ) High temperature soldering ( above 900 0 C )
FORM OF SOLDERING JOINTS Joints design for welding and soldering Soldering gaps Preparing of soldering ( brazing ) gap
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SOLDERING AND BRAZING
CLASSIFICATION (2) METHODS OF SOLDERING
Bit soldering Flame soldering ( torch soldering/brazing = TS/TB) Furnace brazing Dip soldering ( molten chemical and molten metal ) Induction brazing Resistance brazing
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SOLDERING AND BRAZING
CLASSIFICTION (3) FEEDING OF SOLDER BRAZING
ALLOY ( BRAZING FILLER METAL) Soldering with put on solder ( molten chemical
bath system) Soldering with deposit solder Dip soldering (molten metal bath system )
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SOLDERING AND BRAZING
WORKING PROCEDURE ANDPRINCIPLES OF OPERATION (1)
PROCEDURE OF WORKING Pre-cleaning Apply the flux Assembling the components Heating the part Attaining the working temperature Wetting of solder Cooling and cleaning
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SOLDERING AND BRAZING
WORKING PROCEDURE AND PRINCIPLES OFOPERATION (2)
PRINCIPLE OF OPERATION (BASIC STEPS) Choosing the solder and flux Cleaning Fixing the gap (clearance ) Heating Treatment of the soldered/brazed joint
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SOLDERING AND BRAZING
HEATING TIME AND SOLDERINGTEMPERATURE (2)
Soaking temperature Soldering temperature range of the flux Working temperature Brazing temperature
The temperature to which the base metal is heated to enable thefiller to wet the base metal and form a brazed joint
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BRAZING AND SOLDERING
FLUXES (1) DISTINCTION IS MADE FOR DIFFERENT SOLDERING
TEMPERATURES Soldering/brazing temperature 750 0-1100 0C Soldering/brazing temperature 550 0-800 0C Soldering/brazing temperature 500 0-600 0C Soldering/brazing temperature 200 0-300 0C EXAMPLES
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SOLDERING AND BRAZING
FLUXES (2) FUNCTION OF THE FLUXES
Preventing oxidation
Exclusion of air from the brazing face Pushing away the air from the solder gap (capillary attraction) Promoting the fluidity of the brazing solder Promoting the wetting action Flux indicates the working temperature Flux prevents oxidation of the soldering stick
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SOLDERING AND BRAZING
SOLDERS or BRAZING FILLER METALS(BRAZING ALLOYS)
A filler metal used in soldering which has liquidus not
exceeding 8500
F DISTINGUISHED ACCORDING TO THE WORKING
TEMPERATURE : SOFT SOLDER HARD SOLDER (BRAZING FILLER METAL OR ALLOYS)
Brazing alloys for aluminum Silver hard solders Copper phosphorus hard solders Copper hard solders
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SOLDERING AND BRAZINNNG
BRAZING 0R BRAZE WELDING OF STEEL Application
BRAZING AND SOLDERING OF ALUMINUM
Advantages BRAZING AND SOLDERING OF COPPER
Soft soldering Hard soldering