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Main Function of the Oxy-Acetylene Torch:
The primary function of the Oxy-Acetylene Torch is at least three-fold.
1. The torch can be used to braze two or more pieces of metal (they don’t have to be the same type of metal) together.
Brazing is a process of using a brass filler rod that creates a metallic bond between the different pieces of metal. With brazing the two pieces of metal are not 'fused' together; they are merely joined by an 'adhesion' process with the brazing material.
The torch can also weld similar pieces of steel by using a filler rod made of the exact material composition as the metal being fused.
2. The torch can be used as a cutting torch. This cutting torch feature allows items to be cut to length and it also allows material to be removed from the middle of a piece. The cutting torch does not typically leave a very smooth edge -- thus grinding is usually required to finish a cut.
3. The torch can also be used to heat up metal pieces. Someone may want to heat up a piece of metal to bend it or manipulate it into a different shape. Another reason why some use the torch to heat metal would be in the area of TIG welding. When TIG welding a large piece of aluminum it is beneficial to heat the metal up to a certain temperature to speed up the TIG welding process.
Personal Protective Equipment to be used during operation:
Welding goggles required
Leather Apron required
Leather Arm Coverings required
Leather Gloves required
Steel Toe Leather Boots required
Safety Precautions related to Welding:
1. Eyes:
Do not watch the torches flame with your eyes unprotected by a sufficiently darkened glass.
2. Burns:
Aluminum melts at nearly 1500 degrees F.
Steel melts at nearly 3000 degrees F.
Human flesh burns at a lot less than either of the above.
Always wear protective gloves, aprons, arm protection.
Leather boots should be such that a drop of molten steel has no easy path into your boot. If your leather boots are the lace-up type with some type of man-made material on the tongue, you should wear leather feet protectors on top of your boot.
NOTE: Some molten metals will stick to your skin.
3. Clothing:
Never wear frayed clothing that could be caught on fire by sparks.
Never weld while wearing tennis shoes, hot steel will burn into man-made materials, and you won’t be able to get your shoe off fast enough.
4. Hazardous Fumes:
Welding galvanized steel is very dangerous to ones’ health; the galvanized coating on sheet metal has a zinc component in it and this is very bad to breathe in – it can cause serious health problems.
Any flux from a welding rod is intended to shield a weld from the atmospheric air NOT shield lungs from atmospheric air, so exercise caution and try to avoid breathing welding fumes.
The Oxy-Acetylene Torch uses compressed gases in its weld process. Acetylene is an extremely flammable gas and it will take away breathing air if it is released all of a sudden, and especially if used in a confined space. Never weld in a confined space without proper equipment in place.
5. Cylinder usage:
NEVER, NEVER, NEVER USE OIL ON THE THREADS OF A GAS CYLINDER when hooking up gauges!!!! This is a serious explosion hazard. Oxygen is the main culprit of this evil situation, but it is required practice to NEVER put oil on any cylinder's threads where you are hooking up gauges.
It is important to remember that any compressed gas cylinder has the potential of becoming a projectile, if for some reason the contents are allowed to suddenly escape. When a cylinder is in use it must be properly secured to a cart. When any cylinder is being transported, it must have the cap screwed on to protect the valve from accidental damage. When a cylinder is in storage before or after use, it must be properly secured to prevent accidental falling.
Compressed gas cylinders also are potential air robbing devices if the contents are allowed to suddenly escape into the room’s atmosphere.
Never 'crack' a cylinder's valve prior to hooking up the gauges.
When using the OXY-ACETYLENE torch, one must be aware of the fact that a room with only 3% of the air space occupied by a ‘pocket’ of acetylene gas IS a potential explosion hazard.
Be aware of the fact that Acetylene gas is very unstable at high pressures. Actually acetylene cylinders have a significant amount of acetone in the bottom of the tank to act as a stabilizing influence. This is why when you are running out of acetylene, you will notice a change in color of the flame; that is due to the flame now having more acetylene in it that previously.
NEVER use oxygen as a substitute for compressed air.
Basic Operating Procedures for Using an Oxy-Acetylene Torch.
1. Assemble all materials to be welded and have them clamped and prepared for welding.
2. Make sure the oxygen and acetylene cylinders are secured to the cart or the wall.
3. Prior to attaching the gauges you will want to 'crack the cylinder' to remove any dirt from the cylinders valve prior to hooking up the gauges. Follow these directions to safely 'crack' a cylinder:
Stand to the side of the cylinder.
Make sure the cylinder's valve is pointing away from you.
Make certain that any gas coming out of the cylinder's valve will not hit any oily material.
Make certain that the gas that escapes from your cylinder's valve will not create a problem for other activities going on in the area.
Before attaching regulators, open the valve slightly for an instant and then close.
This removes any dust or foreign particles from the area where the gauges are to be attached.
4. Attach the regulators and release the adjusting screw on each of the regulators (this will keep the cylinder's contents from flowing when the main valve is opened).
5. Inspect both oxygen and acetylene hoses for signs of cracking. Do not use if cracking exists.
6. Install the desired torch head; make sure to inspect the o-rings on the torch to make sure there are no signs of cracking or splits.
7. Put on all the required PPE.
8. Locate a striker and make sure it makes a spark when activated.
9. Make sure the valves are closed on the torch head.
10. Stand to the side of the gauges and open the acetylene cylinder slowly, about 1/4 turn (90 degrees). Never open an acetylene cylinder more than 3/4 turn (270 degrees), and never operate acetylene at pressures greater than 15 psi. Acetylene gas is very unstable and it is quite unsafe at high pressures.
11. Make sure the cylinder's Key (used to open the cylinder's valve) stays on the cylinder, in the event that the cylinder needs to be shut off quickly.
12. Using the valves at the torch, purge both oxygen and fuel from the lines prior to lighting the torch.
13. Stand to the side of the gauges and slowly open the oxygen cylinder and eventually open it all the way.
14. With striker in hand, gloves on, welding goggles on you are ready to start the flame.
15. Slightly open the acetylene valve on the torch and then use the striker to ignite the acetylene. Adjust this flame until you have the appropriate flame for what you are trying to do. To adjust this flame you will need to increase or decrease the acetylene pressure, via the adjusting screw, on the gauge mounted on the cylinder. Remember; never operate acetylene gas at pressures greater than 15 psi!!!
16. Once the acetylene flame is established and the flame is stable, you are ready to introduce the oxygen gas into the flame. Turn the adjusting screw on the gauge assembly to the desired pressure. Slowly open the oxygen valve at the torch head and make an adjustment to achieve the desired flame. To develop the flame you desire, you may have to increase or decrease the oxygen pressure at the gauge.
17. Weld as necessary, using precautions to avoid contacting the gas hoses against anything hot.
18. Occasionally you may want to feel the acetylene cylinder and make sure it isn't heating up. If it is heating up shut the acetylene cylinder immediately.
19. When you are finished welding, the acetylene valve at the torch should be closed first, and then the oxygen valve should be closed secondly.
20. With both valves closed at the torch, you should then close the valves on both the oxygen and acetylene cylinders.
21. Now that the cylinders valves are closed, open the torches valves and relieve the pressure off the gauges.
22. Release the adjusting screws on the gauges so that the next time you hook them up, they will be in the correct state.
23. Put all equipment away and clean up after yourself.
