presentation 1b 102a b 1.13 b 1.17 ver 2

8/10/2019 Presentation 1B 102a B 1.13 B 1.17 Ver 2

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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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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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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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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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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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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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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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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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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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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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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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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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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

presentation 1b 102a b 1.13 b 1.17 ver 2

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