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Sem 1 Brazing With Oxyacetylene Welding

This document provides instructions for brazing with oxyacetylene welding. It discusses the key differences between brazing and fusion welding, including that the base metal is not melted and an alloy bronze filler rod is used. The document then outlines the procedure for lighting the torch and running a practice braze bead on a steel sheet with a bronze rod. Students are instructed to practice lighting the torch and running beads with variations in torch technique and flux application.

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Kamarul Nizam
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322 views3 pages

Sem 1 Brazing With Oxyacetylene Welding

This document provides instructions for brazing with oxyacetylene welding. It discusses the key differences between brazing and fusion welding, including that the base metal is not melted and an alloy bronze filler rod is used. The document then outlines the procedure for lighting the torch and running a practice braze bead on a steel sheet with a bronze rod. Students are instructed to practice lighting the torch and running beads with variations in torch technique and flux application.

Uploaded by

Kamarul Nizam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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University Kuala Lumpur Malaysia France Institute

FWB22303 Joining Technology

1. Brazing with Oxyacetylene Welding

This brazing exercise will give you experience in running beads with bronze rod. The
beads must be uniform in size, straightness and appearance. It will take a great deal of
practice since you will be working with different materials and a different process
than in fusion welding.

The main differences you should be aware of as you braze are these:
1. The base metal is not melted.
2. An alloy bronze filler rod is being used.
3. Different techniques are used in applying the flux.
4. Torch and rod motion to form a good bead are different.

Carefully study the plan below and cut or shear the material to size. Use the same size
tip as selected for fusion welding the same thickness base metal. Select a 1 – 2 mm
diameter bronze rod and an appropriate flux. It is a good practice to check with your
instructor for manufacturer's specifications on what type of alloy rod and flux to use
for each job.

1 – 2 mm

50 mm

100 mm

2. LIGHTING THE TORCH

The procedure for lighting the welding torch should be followed carefully. By doing
so, the desired flame adjustment can be obtained with minimum danger to the welder
and the welding equipment. The basic steps for lighting the torch are as follows:

1. Before opening the oxygen or acetylene cylinder valve be sure the regulator
screws have been backed off and freely. The torch needle valves should also be
turned off. This is simply a safe operating precaution.
2. Slowly open the acetylene cylinder valve approximatelyhalf turn.
3. Slowly open the oxygen cylinder valve as far as it will go.
4. Next, turn the acetylene and oxygen regulator adjusting screws to the desired
working pressures.
5. Open the acetylene needle valve on the torch about three quarters of a turn.
6. As quickly as possible, light the acetylene with a spark lighter, and adjust the
flame until it burns from the tip. Considerable smoke with clumps of carbon in it
indicates the acetylene flame is too small. Increase the amount of acetylene as

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University Kuala Lumpur Malaysia France Institute
FWB22303 Joining Technology

necessary to avoid this condition. NEVER light the torch with a match. Use an
approved spark lighter.
7. Open the oxygen needle valve slowly. The orange colored acetylene flame will
turn to a light blue, with a bright, feather shaped flame inside. Continue to open
the oxygen valve until the feather shaped flame is reduced to a small cone at the
torch tip.

The flame with the small cone at the tip is called a NEUTRAL flame and is used in
most all welding operations. Minor adjustments in the regulator pressures and at the
needle valves are often necessary to produce this flame.

3. Practice 1: RUNNING A BEAD WITH BRONZE ROD

PROCEDURE

1. Prepare welding station as usual manner.


2. Position the steel sheet flat on the welding table and clean the length of the center
area with wire brush.
3. Adjust the torch to a neutral or slightly oxidizing flame.

4. Heat the end of the rod and dip it into the flux. Apply only enough heat so that a
light coating of flux will stick to the rod.
5. Direct the flame on the right edge of the steel sheet and heat only to a dull cherry
red. The width of the bead is determined by how wide you heat the area to a
cherry red. Try to keep the bead about 12 mm wide.
6. Touch the rod to the heated area and allow some flux to melt on the surface.
Quickly melt off a drop of rod metal and allow it to flow to the desired bead
width.
7. Add more rods metal for the required bead size and begin brazing. Do not let the
inner cone of the flame contact the molten alloy.
8. As the braze progresses, use the normal weaving pattern with the torch. However,
an alternating up-and-downmotion of both torch and rod should be used if
necessary.When the rod is down draws it in the brazing direction before pulling it
away. This action will cause the flux to flow a head of the molten alloy, both
cleaning the surface quicker and providing a path for the braze bead.
9. When the flux no longer leads the bead, dip the hot filler rod in the flux and
continue brazing. Examine the completed bead for straightness, uniform width
and height and an even ripple. Practice running beads until you can consistently
make them to acceptable standards.

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University Kuala Lumpur Malaysia France Institute
FWB22303 Joining Technology

4. Your task

1. Under the supervision of your instructor, go through the correct steps in lighting
the welding torch. Practice these steps until you become very familiar with the
process.
2. Practice running more beads but change the procedure for each as follows:
a. Move the torch in the standard weaving pattern but do not use the up and
down motion.
b. Adjust the torch to a slightly reducing flame.
c. Apply a very small amount of flux to the bronze rod. After making each of
these practice beads, carefully examine them and notice the results of each
procedure.

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