What is a welding flame?
Welding flames are produced when slightly more than one volume of oxygen is mixed with one volume of acetylene. To obtain this type of flame, the torch should first be adjusted to a neutral flame. The oxygen flow is then increased until the inner cone is shortened to about one-tenth of its original length.
How many welders truly adore their welding torch? No one knows, but flame welding is the one welding procedure that is appreciated and valued above others. Let’s follow the lovers and learn about the flame welding technique. Let the begin!
Weld and welding: what's the difference?
Welding is the process of joining two or more parts into a continuous structure. “Welding” refers to the process, while “weld” refers to the joint created by this process. I’ve been slapped on the wrist before for not understanding the difference. First and foremost, get off to a solid start!
What does a welding torch assembly look like?
Everyone has heard the phrase, but the dual gas blowtorch is a world apart from the blow torch held in one hand and used in plumbing or caramelizing a crème brulée. We’re discussing metal melting here!
The bi-gas torch that can be used for a variety of tasks (also known as a soldering lamp)
Plumbers have used this for generations to braze, bend, or tin-plate pipes. It consists of a butane or propane cylinder or disposable cartridge, a pre-set regulator, and a hose connected to a handle with a heating control knob. An interchangeable burner allows you to attain temperatures of up to 2912°F through flame contact. Depending on the job, the cartridges have a maximum life of one to two hours.
In contrast to the mono-gas system described above, an oxidizer – oxygen – is added to achieve an optimal temperature of 5072°F-5432°F. Bi-gas torch sets are well-presented and compact, easy to store, and ideal for minor plumbing repairs as well as autogenous welding beginners. In addition, extra-small nozzles for jewelry repair are included in the set. The length of use is again limited.
Welding with autogenous or oxyacetylene
This bi-gas system, which is employed in industrial and modern plumbing applications, consists of the following components:
- Bottled acetylene dissolved at 17 bars; the “warhead” (top of the bottle) is color-coded brown.
- As an oxidizer, a cylinder of oxygen pressurized to 195 bars; a white warhead;
- Two pressure regulators that can be adjusted separately;
- Two flexible hoses, one blue for oxygen and the other red for acetylene;
A specialized torch that ensures that the two gases are mixed properly. With interchangeable nozzles of various sizes, different levels of precision can be achieved.
Why is oxyacetylene welding so popular among welders?
- It’s scorching – between 5612°F and 5792°F – and produces three distinct heat zones: the tip, the pink plume (ooh, gorgeous!), and the blue-colored decreasing zone, which is critical for autogenous welding. That’s something I learned from a metalwork teacher many years ago, and it’s something you’ll never forget once you’ve mastered it.
- With a variety of interchangeable nozzles on a star-shaped platform, it’s simple to adjust. These are always included with the torch and are categorized by flow rate in liters per minute. To provide a faultless flame tip, they must be kept clean at all times: a competent welder keeps his welder’s reamer in his pocket at all times.
Advice on installation
To prevent the flame from recoiling into the gas bottles, a one-way valve, the same in color as the hose in question, is installed on each hose as close to the
What is the purpose of a flame welder?
All you have to do for single gas setups is heat to the melting point of the filler metal (e.g., tin or silver solder), remembering to strip your components beforehand. The welded components themselves are not melted in this situation. In the welding process, just the filler metal is melted.
Therefore, melting temperatures differ amongst metals, considering the qualities of your filler metal while selecting equipment and operating conditions.
Different burners are used to concentrate the heat at the point of welding, depending on the size of the component to be welded. You can obtain special nozzles for difficult welding that prevent damage to the surrounding region.
A bi-gas torch can be used to heat a component before shaping it, remove paint from sheet metal, and even produce creme brulee!
The focus here is on autogenous welding, which is comparable to bi-gas welding but more complex.
What are the different types of welding torches?
A flow rate of 100 l/min per 0.039 inches of thickness is roughly correct as a rule of thumb; the wire diameter of your filler metal is equal to the thickness of your sheet metal. Clearly, No. 2 below is more suited to heating forged metal components!
Classification of welding torches
Nozzles with flow rates ranging from 10 to 40 l/min; tiny welding torch
Torches with nozzles ranging from 50 to 200 l/min are the most prevalent.
Nozzles with flow rates ranging from 250 to 1000 l/min; high-temperature torch
Heavy-duty welding torch; nozzles ranging from 1250 to 5000 l/min.
Use of a flame welder for the first time
Turn up the acetylene first, then the oxygen (a quarter-turn of the bottle cock should suffice); finally, light your torch with the designated gas ignition button and adjust your flame to a fine, sharp tip.
Try melting some metal sheet to practice your melting skills – it doesn’t matter if you make a few holes the first time; the point is that you’re learning!
After you’ve mastered melting, try welding with a suitable filler metal (diameter and type).
To begin with, it’s usual for molten metal droplets to fly everywhere while you’re figuring out your settings, so keep an eye on your work clothing! Repeat until you’ve found the best locations for your needs.
A word of caution concerning your acetylene bottle: Since the gas is dissolved in acetone, avoid entirely emptying it and don’t lay it down; both will result in acetone burning in your torch, resulting in a smoky flame and poor welding outcomes.
Advice from users
If you want to save money, purchase a gadget that automatically starts and stops the gas flow when you attach or detach your torch.
Accidents and faults that occur frequently
Malfunctions are inevitable due to the nature of the gadget; yet, most of the time, there’s nothing to be concerned about!
It is caused by a drop in one of the gases’ pressures or a problem with the torch.
The noise of clicking or snapping
Either the torch nozzle aperture is blocked, in which case you should clean it with a welder’s reamer, or the nozzle is overheating, in which case you should cut the acetylene and leave the oxygen on to cool it down.
Inside the torch, there are visible flames.
Overheating of the nozzle is the cause; cut off the gas supply and restart.
A sooty flame
When the flame turns black and nasty, it’s time to put it out. Check to see if your gas flow has been appropriately adjusted.
Advice on how to choose
To recap, selecting a welding torch requires a thorough understanding of the spectrum of tasks it must do. You’ll find an outstanding choice of products to suit you now that you’ve narrowed down your options.
Allow yourself to be drawn in by the gorgeous colored glow of your ideal welding torch… But be careful not to get too near!