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Jedi Knight
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Proper use of your Oxy/Acetylene Torch
Bottles:
The acetylene bottle should never be placed on its side always stand it erect. It contains acetone and placing the bottle on its side gives the probability that the acetone can get into your hose, acetone and rubber do not mix well, and the hose will be damaged causing leakage. Not to mention what it will do to your regulators.
Proper valve usage
The valve on the acetylene bottle should be turned no more than half a turn on for safety purposes , when turning your acetylene bottle on be sure to check for leakage around the valve and regulator. {Easy to smell} If the packing in the valve becomes worn, loose, or damaged you should not use the bottle, remove it from use immediately. Especially with the acetylene valve, it is necessary to take all precautions to prevent leakage due to it`s volatile nature. A spark from the welding process can and will start it on fire if it is leaking. Acetylene is unstable at pressures above 15 P.S.I. and High pressure can ignite it.
Regulators:
The acetylene regulator should never be set any higher than 15 P.S.I. any higher and you risk a violent explosion! And acteone drawoff into your regulator and hose. If you can accomplish your welding task at a lower setting than 15 P.S.I by all means do so. Normaly very large tips like a rosebud {used for heating purposes} are the only tips that require the higher setting of 14 to 15 P.S.I. The oxygen regulator should be set to around 40 P.S.I.. It can be set higher but there is no need unless you are cutting very thick material {4 inches or more} when you are finished using the torch set, you should release the adjustment screws on both regulators so there is NO pressure what so ever on the regulator diaphrams and firmly turn both bottles completely off. Release all pressure form the hoses by cracking the torch valves. If you are inside an enclosed area like a garage make sure there is ample air circulation to clear any lingering gasses out of the area before closing the door.
Flashback preventers: Should be installed on each regulator and one on each hose connection on your mixing chamber. These prevent any combustion from entering your hoses or regulators, they can be purchased at any local welding supply source.
Mixing Chamber: When attaching a welding or cutting head to your mixing chamber, snug, just over hand tight is all you need. If you experience leakage at the joint you either need to replace the o ring or replace the whole mixing chamber DO NOT over tighten the attachments to the mixing chamber.
Mixing chamber valves: The same applies here a snug hand tightness is all that is required any tighter and you will damage the seats causing them to forever leak!
Hose Upkeep: Your hoses should last for years, several ways to ensure they do is.
Never spray sparks on them while cutting, welding or grinding.
Try not to drag them across sharp or hot objects.
Keep them coiled up on thier cart hose holder when not in use.
Keep them clean, wipe them off periodicaly with a rag and soapy water.
Keep your hoses out of the sun as much as possible.
Do not drop heavy objects on your hoses.
Safety:
Before starting any welding process the proper safety equipment is essential
Goggles: use as dark a shade as possible when welding with any process. You only have one set of eyes, protecting them is essential. Sun glasses {No matter how dark the shade is} are NOT recommended. They can if the circumstances are just right allow foreign debris in your eyes. It is not fun having hot molten metal come in contact with your eye. Use the proper goggles or welding shield/Helmet. Never look directly at any weld flame or arc with your naked eyes. Even the reflection coming off of the walls can cause severe damage. By all means take the time and precautions to protect yourself.
Earplugs: are essential safety equipment use them faithfully you won`t regret it in the end.
Loose ragged clothing and welding DO NOT go together, they are a fire hazard. Flammable liquids paint, grease, solvents, gasoline, ETC. are a no no when performing welding tasks remove them from your environment before performing welding tasks.
Gloves {leather} will prevent you from becoming severely burnt, use them when ever possible.
And by all means remember: Your Oxy/Acetylene cutting head is NOT A HAMMER!
DO NOT USE IT FOR ONE! {You would not believe how many so called professional welders I have seen use the back side of their cutting head to knock away a piece of metal they have just cut.}
Ok down to the nitty gritty
Tip selection :
Use as small a torch tip as you possibly can to accomplish the task at hand the reason is the larger the tip the larger the heat affected zone is. You want/need to keep the heat affected zone to a minimum and with a small tip you can control the distortion much easier.
Igniting the torch:
Secure all hose connections firmly {Do Not over tighten}. Set your regulators to their proper adjustments. Crack the acetylene valve on the mixing chamber slightly, using a striker try striking a flame {this may take several attempts due to the acetylene line {hose} being purged previously. Once you have flame turn the acetylene valve on the mixing chamber until you attain a flame that is not producing black soot, the flame should still be in direct contact with the torch tip. If it isn`t that means you have too much acetylene flow, turn it down until it contacts the torch tip. Next crack the oxygen valve on the mixing chamber increase the flow until you see a blue well defined cone at the torch tip, fuzzy or blurry cone means not enough oxygen. Once you attain a sharp well defined cone at the torch tip this is the top end of the heat range for that size tip. The heat range can be turned down to a point. To do this start with the oxygen valve on the mixing chamber, go slowly decreasing the flow. Then go to the acetylene valve on the mixing chamber and do the same until you attain that sharp well defined cone again. Once you attain the desired heat range for your purposes. Begin welding, soldering or brazing.
If you experience detonation or explosions while welding one of three things are wrong. #1 The welding tip you have choose is too big for the heat setting you are using.
What causes detonation is the gas mixture is combusting inside of the welding tip due to inadequate gas flow {the heat setting for this tip is turned down to low}.
Remedy: choose the next size smaller tip and begin again.
#2 A dirty tip can cause detonation as well. Usually a dirty tip will not attain a well defined blue cone next to the tip
#3 An overheated tip {using it in an enclosed area or holdding it too close to the metal you are welding}
Remedy: Turn off the gas and clean the tip.
Tip cleaning: Use the proper size tip cleaner for the orifice on the welding tip to be cleaned. Sometimes spatter enters these tips and it is necessary to remove it in order to attain a proper flame. Slide the tip cleaner in and pull it out of the tip at as close to a 90 degree angle as possible, these tip cleaners have an abrasive action and any distortion of the orifice of the weld tip will render it basically useless.
{Here is a technique that is kind of a barnyard approach but I have found it works and keeps me from abrading my tips. A piece of wood, a 2x4 or a piece of oak from an old pallet, basically any kind of wood will do. While the torch is ignited briskly rub it on the wood at a slight angle. Yes you will hear detonation this is normal. Then check the flame, adjust it if necessary to attain that same well defined blue cone. If after rubbing the ignited torch on the wood you can not attain the proper adjustment then you will need to turn the flame off and use the wire type tip cleaners to remove the obstruction causing improper adjustment.}
Note: DO NOT attempt this barnyard approach without flashback preventers in place and a spray water bottle and reliable fire extinguisher handy. use the spray bottle to extinguish the smoldering wood.
NEVER weld anything without a reliable fire extinguisher handy.
If you see the flame go out, and see soot emerging from the tip, and hear a whistling sound turn the mixing chamber valves off immediately! This means there is ignition inside of the tip. This condition is caused by placing the welding tip flat at a 90 degree angle while ignited on the wood. It is imperative that you DO NOT do this, Maintain a slight angle at all times while using this approach. All adjustments and cleaning techniques apply to cutting tips as well, with one exception and that is the forward valve on your cutting head. After you attain a neutral flame {in this case the well defined blue cones} turn the forward valve on wide open. Depress the cutting lever and look at the blue cones if they have become fuzzy or blurry while depressing the lever, adjust the rear oxygen valve until the well defined blue cones re appear. You are now ready to begin cutting
Clarification: the flame has two parts the blue cone next to the tip itself and the feather {the rest of the flame}
While cutting or welding a slight leading angel is what you want, the blue cone or cones should be in close proximity to the material to be welded or cut. In other words, nearly touching the metal. Detonation or explosions while cutting means the same thing as described above for welding tips. {tip too large for the heat setting or dirty tip.}
Let the metal become molten or liquid before depressing the cutting lever, move at a steady even pace. If done properly you should hear a steady sputtering sound and when complete you should have minimal slag on the reverse side. A lot of slag means one of several things.
#1 Tip adjusted too hot.
#2 Travel speed is too slow
#3 A dirty tip
Correct tip selection and adjustment in either cutting or welding is the key to attaining a desirable weld or cut. This comes with experience and practice
REMEMBER oxy/acetylene gas is highly volatile, a leaking bottle, hose, or valve has the potential to cause a severe explosion resulting in destruction and death. If you smell Acetylene in your garage or building when you are not using your torch investigate immediately and by all means do not have an open ignition source {cigarette, cigar or sparks ETC.} present.
The next article will cover soldering lead and silver.
Kerry
Bottles:
The acetylene bottle should never be placed on its side always stand it erect. It contains acetone and placing the bottle on its side gives the probability that the acetone can get into your hose, acetone and rubber do not mix well, and the hose will be damaged causing leakage. Not to mention what it will do to your regulators.
Proper valve usage
The valve on the acetylene bottle should be turned no more than half a turn on for safety purposes , when turning your acetylene bottle on be sure to check for leakage around the valve and regulator. {Easy to smell} If the packing in the valve becomes worn, loose, or damaged you should not use the bottle, remove it from use immediately. Especially with the acetylene valve, it is necessary to take all precautions to prevent leakage due to it`s volatile nature. A spark from the welding process can and will start it on fire if it is leaking. Acetylene is unstable at pressures above 15 P.S.I. and High pressure can ignite it.
Regulators:
The acetylene regulator should never be set any higher than 15 P.S.I. any higher and you risk a violent explosion! And acteone drawoff into your regulator and hose. If you can accomplish your welding task at a lower setting than 15 P.S.I by all means do so. Normaly very large tips like a rosebud {used for heating purposes} are the only tips that require the higher setting of 14 to 15 P.S.I. The oxygen regulator should be set to around 40 P.S.I.. It can be set higher but there is no need unless you are cutting very thick material {4 inches or more} when you are finished using the torch set, you should release the adjustment screws on both regulators so there is NO pressure what so ever on the regulator diaphrams and firmly turn both bottles completely off. Release all pressure form the hoses by cracking the torch valves. If you are inside an enclosed area like a garage make sure there is ample air circulation to clear any lingering gasses out of the area before closing the door.
Flashback preventers: Should be installed on each regulator and one on each hose connection on your mixing chamber. These prevent any combustion from entering your hoses or regulators, they can be purchased at any local welding supply source.
Mixing Chamber: When attaching a welding or cutting head to your mixing chamber, snug, just over hand tight is all you need. If you experience leakage at the joint you either need to replace the o ring or replace the whole mixing chamber DO NOT over tighten the attachments to the mixing chamber.
Mixing chamber valves: The same applies here a snug hand tightness is all that is required any tighter and you will damage the seats causing them to forever leak!
Hose Upkeep: Your hoses should last for years, several ways to ensure they do is.
Never spray sparks on them while cutting, welding or grinding.
Try not to drag them across sharp or hot objects.
Keep them coiled up on thier cart hose holder when not in use.
Keep them clean, wipe them off periodicaly with a rag and soapy water.
Keep your hoses out of the sun as much as possible.
Do not drop heavy objects on your hoses.
Safety:
Before starting any welding process the proper safety equipment is essential
Goggles: use as dark a shade as possible when welding with any process. You only have one set of eyes, protecting them is essential. Sun glasses {No matter how dark the shade is} are NOT recommended. They can if the circumstances are just right allow foreign debris in your eyes. It is not fun having hot molten metal come in contact with your eye. Use the proper goggles or welding shield/Helmet. Never look directly at any weld flame or arc with your naked eyes. Even the reflection coming off of the walls can cause severe damage. By all means take the time and precautions to protect yourself.
Earplugs: are essential safety equipment use them faithfully you won`t regret it in the end.
Loose ragged clothing and welding DO NOT go together, they are a fire hazard. Flammable liquids paint, grease, solvents, gasoline, ETC. are a no no when performing welding tasks remove them from your environment before performing welding tasks.
Gloves {leather} will prevent you from becoming severely burnt, use them when ever possible.
And by all means remember: Your Oxy/Acetylene cutting head is NOT A HAMMER!
DO NOT USE IT FOR ONE! {You would not believe how many so called professional welders I have seen use the back side of their cutting head to knock away a piece of metal they have just cut.}
Ok down to the nitty gritty
Tip selection :
Use as small a torch tip as you possibly can to accomplish the task at hand the reason is the larger the tip the larger the heat affected zone is. You want/need to keep the heat affected zone to a minimum and with a small tip you can control the distortion much easier.
Igniting the torch:
Secure all hose connections firmly {Do Not over tighten}. Set your regulators to their proper adjustments. Crack the acetylene valve on the mixing chamber slightly, using a striker try striking a flame {this may take several attempts due to the acetylene line {hose} being purged previously. Once you have flame turn the acetylene valve on the mixing chamber until you attain a flame that is not producing black soot, the flame should still be in direct contact with the torch tip. If it isn`t that means you have too much acetylene flow, turn it down until it contacts the torch tip. Next crack the oxygen valve on the mixing chamber increase the flow until you see a blue well defined cone at the torch tip, fuzzy or blurry cone means not enough oxygen. Once you attain a sharp well defined cone at the torch tip this is the top end of the heat range for that size tip. The heat range can be turned down to a point. To do this start with the oxygen valve on the mixing chamber, go slowly decreasing the flow. Then go to the acetylene valve on the mixing chamber and do the same until you attain that sharp well defined cone again. Once you attain the desired heat range for your purposes. Begin welding, soldering or brazing.
If you experience detonation or explosions while welding one of three things are wrong. #1 The welding tip you have choose is too big for the heat setting you are using.
What causes detonation is the gas mixture is combusting inside of the welding tip due to inadequate gas flow {the heat setting for this tip is turned down to low}.
Remedy: choose the next size smaller tip and begin again.
#2 A dirty tip can cause detonation as well. Usually a dirty tip will not attain a well defined blue cone next to the tip
#3 An overheated tip {using it in an enclosed area or holdding it too close to the metal you are welding}
Remedy: Turn off the gas and clean the tip.
Tip cleaning: Use the proper size tip cleaner for the orifice on the welding tip to be cleaned. Sometimes spatter enters these tips and it is necessary to remove it in order to attain a proper flame. Slide the tip cleaner in and pull it out of the tip at as close to a 90 degree angle as possible, these tip cleaners have an abrasive action and any distortion of the orifice of the weld tip will render it basically useless.
{Here is a technique that is kind of a barnyard approach but I have found it works and keeps me from abrading my tips. A piece of wood, a 2x4 or a piece of oak from an old pallet, basically any kind of wood will do. While the torch is ignited briskly rub it on the wood at a slight angle. Yes you will hear detonation this is normal. Then check the flame, adjust it if necessary to attain that same well defined blue cone. If after rubbing the ignited torch on the wood you can not attain the proper adjustment then you will need to turn the flame off and use the wire type tip cleaners to remove the obstruction causing improper adjustment.}
Note: DO NOT attempt this barnyard approach without flashback preventers in place and a spray water bottle and reliable fire extinguisher handy. use the spray bottle to extinguish the smoldering wood.
NEVER weld anything without a reliable fire extinguisher handy.
If you see the flame go out, and see soot emerging from the tip, and hear a whistling sound turn the mixing chamber valves off immediately! This means there is ignition inside of the tip. This condition is caused by placing the welding tip flat at a 90 degree angle while ignited on the wood. It is imperative that you DO NOT do this, Maintain a slight angle at all times while using this approach. All adjustments and cleaning techniques apply to cutting tips as well, with one exception and that is the forward valve on your cutting head. After you attain a neutral flame {in this case the well defined blue cones} turn the forward valve on wide open. Depress the cutting lever and look at the blue cones if they have become fuzzy or blurry while depressing the lever, adjust the rear oxygen valve until the well defined blue cones re appear. You are now ready to begin cutting
Clarification: the flame has two parts the blue cone next to the tip itself and the feather {the rest of the flame}
While cutting or welding a slight leading angel is what you want, the blue cone or cones should be in close proximity to the material to be welded or cut. In other words, nearly touching the metal. Detonation or explosions while cutting means the same thing as described above for welding tips. {tip too large for the heat setting or dirty tip.}
Let the metal become molten or liquid before depressing the cutting lever, move at a steady even pace. If done properly you should hear a steady sputtering sound and when complete you should have minimal slag on the reverse side. A lot of slag means one of several things.
#1 Tip adjusted too hot.
#2 Travel speed is too slow
#3 A dirty tip
Correct tip selection and adjustment in either cutting or welding is the key to attaining a desirable weld or cut. This comes with experience and practice
REMEMBER oxy/acetylene gas is highly volatile, a leaking bottle, hose, or valve has the potential to cause a severe explosion resulting in destruction and death. If you smell Acetylene in your garage or building when you are not using your torch investigate immediately and by all means do not have an open ignition source {cigarette, cigar or sparks ETC.} present.
The next article will cover soldering lead and silver.
Kerry
