1 copyright 2004 lincoln global inc. oxyfuel gas welding & cutting principles of the processes

11Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.

Oxyfuel GasOxyfuel GasWelding & CuttingWelding & Cutting

Principles of the Principles of the ProcessesProcesses

22

Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.

Bead without Filler MetalBead without Filler Metal Bead with Filler MetalBead with Filler Metal

Principles of the OFW ProcessPrinciples of the OFW Process

33


Principles of the OFC ProcessPrinciples of the OFC Process

44


Which Fuel Gas?Which Fuel Gas?

• AcetyleneAcetylene• Methylacetylene-propadieneMethylacetylene-propadiene

• MAPPMAPP

• Propylene Propylene • PropanePropane• Natural GasNatural Gas

• MethanMethan

55


Fuel Gas Technical Data

Acetylene MAPP Propylene Propane Natural Gas

Neutral Flame Temperature 5589oF 5301oF 5250oF 4579oF 4820oF

Oxygen Fuel Combination Ratio 2.5:1 4.0:1 4.5:1 5.0:1 2.0:1

BTU's Per Cubic Foot 1470 BTUs 2460 BTUs 2400 BTUs 2243 BTUs 1000 BTUs

Burning Velocity in Oxygen 22.7 Ft/Sec 15.4 FT/Sec 15.0 Ft/Sec 12.2 Ft/Sec 15.2 Ft/Sec

Fuel Gas CharacteristicsFuel Gas Characteristics

66




Flammability Limits in Oxygen 3-93% 2.5-60% 2.5-60% 2.4-57% 5-59%

Flammability Limits in Air 2.5-80% 3.4-10.8% 2.0-11.1% 2.3-9.5% 5.3-14%

Specific Gravity (air = 1@60oF) 0.91 1.48 1.48 1.52 0.62

Fuel Gas Characteristics Fuel Gas Characteristics - continued- continued

77




Lbs./Gal. Liquid - - 4.80 4.80 4.35 4.28

Cu. Ft./ Lb. Gas 14.60 8.85 9.00 8.66 23.60

Cu. Ft./ Gal. Liquid - - 43.50 43.50 43.00 37.00

Fuel Gas Characteristics Fuel Gas Characteristics - continued- continued


Oxyfuel Gas Oxyfuel Gas Welding & CuttingWelding & Cutting

EquipmentEquipment

99


Oxygen CylinderOxygen Cylinder Acetylene CylinderAcetylene Cylinder

FlammableFlammable

Shock Shock SensitiveSensitive

High High Pressure Pressure HazardHazard

Vigorously Vigorously Supports Supports

CombustionCombustion

Fusible Fusible PlugsPlugs

Safety Safety DiscDisc

HollowHollow

Monolithic Monolithic Porous Porous

Filler Filler MaterialMaterial

1/71/7thth Rule Rule

CylindersCylinders

1010


Oxygen Cylinder ValvesOxygen Cylinder Valves

Disc Ruptures Disc Ruptures If Pressure If Pressure

Goes Too HighGoes Too High

From Oxygen CylinderFrom Oxygen Cylinder

HandwheelHandwheel

Packing NutPacking Nut

Lower Valve Lower Valve Seat Seat

Upper Valve Upper Valve SeatSeat

To Oxygen To Oxygen RegulatorRegulator

CGA 540CGA 540

1111


Acetylene Cylinder ValvesAcetylene Cylinder Valves

To Acetylene To Acetylene RegulatorRegulator

From From Acetylene CylinderAcetylene Cylinder

Lower ValveLower ValveSeatSeat


HandwheelHandwheel


CGA 510CGA 510 CGA 300 CGA 300


From From Acetylene CylinderAcetylene Cylinder

1212


Acetylene Cylinder ValvesAcetylene Cylinder Valves - Linde (Presti-Lite)- Linde (Presti-Lite)

From Acetylene From Acetylene CylinderCylinder



Lower Valve Lower Valve SeatSeat

Valve StemValve Stem


Tee Wrench

Tank Wrench

CGA 510CGA 510

1313


To Fuel To Fuel RegulatorRegulator

Valve Relieves Valve Relieves Excess Excess

Pressure Then Pressure Then Re-seats ItselfRe-seats Itself

HandwheelHandwheel



Lower Valve Lower Valve Seat Seat

Alternate Fuel Cylinder ValvesAlternate Fuel Cylinder Valves

CGA 510CGA 510

From Fuel From Fuel RegulatorRegulator

1414


OFW & OFC Equipment ComponentsOFW & OFC Equipment Components

• Oxygen RegulatorOxygen Regulator• Fuel Gas RegulatorFuel Gas Regulator• Gas HosesGas Hoses• Torch HandleTorch Handle• MixerMixer• Welding TipsWelding Tips• Cutting Attachment Cutting Attachment • Cutting Tips Cutting Tips • Filler Metal OptionalFiller Metal Optional• Gas IgniterGas Igniter

1515


Oxygen RegulatorOxygen Regulator Fuel Gas RegulatorFuel Gas Regulator

RegulatorsRegulators

1616


Combination Welding Torch with Mixer and Welding TipCombination Welding Torch with Mixer and Welding Tip

OFW EquipmentOFW Equipment

1717


Straight Cutting TorchStraight Cutting Torch

Combination Cutting Torch with Cutting AttachmentCombination Cutting Torch with Cutting Attachment

OFC EquipmentOFC Equipment

1818


Torch & Cutting ValvesTorch & Cutting Valves

1919


High Turbulence

Oxy/Fuel Mix

Equal (Positive) Pressure MixerEqual (Positive) Pressure Mixer

Injector (Low Pressure) MixerInjector (Low Pressure) Mixer

Oxygen

Fuel Gas

Fuel Gas

Oxy/Fuel Mix

Fuel Gas

Fuel Gas

Oxygen

Mixer DesignMixer Design

2020




OxygenOxygen

Fuel GasFuel Gas

Torch HeadTorch Head

Mixer NutMixer NutMixerMixer

Mixer Design Mixer Design - Continued- Continued

TipTip

Fuel GasFuel Gas

OxygenOxygen

Torch HeadTorch Head

2121



OFC Head Mix DesignOFC Head Mix Design

2222



OFC Head Mix DesignOFC Head Mix Design



RegulatorsRegulators

2424


Which Regulator?Which Regulator?

Single Stage RegulatorSingle Stage Regulator

• Use When Slight Rise in Delivery Pressure from Full Use When Slight Rise in Delivery Pressure from Full

to Empty Cylinder Condition Can Be Toleratedto Empty Cylinder Condition Can Be Tolerated

Two Stage RegulatorTwo Stage Regulator

• Use When a Constant Delivery Pressure from Full to Use When a Constant Delivery Pressure from Full to

Empty Cylinder Condition is RequiredEmpty Cylinder Condition is Required

2525


Adjusting ScrewAdjusting Screw

Primary SpringPrimary Spring

Gas From Gas From Cylinder Cylinder

BonnetBonnet

Flexible Flexible DiaphragmDiaphragm

Gas To Torch Gas To Torch

Regulator BodyRegulator Body

Secondary Secondary SpringSpring

Single Stage Regulator Single Stage Regulator

2626


Secondary Secondary SpringSpring

Cylinder Pressure Cylinder Pressure GaugeGauge


Bonnet Bonnet

Adjusting Adjusting Screw Screw


Gas To Gas To TorchTorch

Working Working Pressure GaugePressure Gauge

Gas From Gas From Cylinder Cylinder

CapsuleCapsule

Primary Primary SpringSpring

CutawayCutaway

2727


Flow Chart Flow Chart

2828


Gas From CylinderGas From Cylinder


Pre-Set First StagePre-Set First Stage


Adjusting Adjusting ScrewScrew

Primary Spring Primary Spring Second Stage Second Stage

Gas To TorchGas To Torch

Primary Spring Primary Spring First StageFirst Stage

BonnetBonnet

Adjustable Adjustable Second StageSecond Stage

Secondary SpringSecondary Spring

Two Stage Regulator Two Stage Regulator

2929


Bonnet Bonnet

Adjusting Adjusting ScrewScrew

Flexible Flexible DiaphragmDiaphragm Gas To Torch

Primary SpringPrimary Spring

Gas From Cylinder Gas From Cylinder

Cylinder Pressure Cylinder Pressure GageGage

Working Working Pressure GagePressure Gage

Primary Primary

SpringSpring

Bonnet Bonnet

CapsuleCapsule

CapsuleCapsule

Regulator BodyRegulator Body Secondary SpringSecondary Spring

CutawayCutaway

3030


Flow ChartFlow Chart


Oxyfuel Gas WeldingOxyfuel Gas Welding

Torch Handles, Mixers, Torch Handles, Mixers, Tubes & Tips Tubes & Tips

3232


Oxygen ValveOxygen Valve

Acetylene ValveAcetylene Valve

OxygenOxygen

AcetyleneAcetylene

MixerMixer

Mixed GasesMixed Gases

TipTip HandleHandle

OFW Torch Handles OFW Torch Handles

3333


WELDING TIP SELECTION CHART

Thickness Tip Diameter of Oxygen Acetylene Oxygen Acetyleneof Metal Size Welding Rod Pressure Pressure Consumption Consumption

In Inches Number In Inches (P.S.I.G.) (P.S.I.G.) (SCFH) (SCFH)

1/64" 0 - - - - 1 1 2.2 21/32" 1 - - - - 1 1 3.3 33/64" 2 1/16" 2 2 4.4 41/16" 3 1/16" 3 3 5.5 53/32" 4 3/32" 4 4 6.6 61/8" 5 3/32" 5 5 8.8 83/16" 6 1/8" 6 6 11.0 101/4" 7 1/8" 7 7 14.3 135/16" 8 5/32" 8 8 17.6 163/8" 9 5/32" 9 9 22.0 201/2" 10 3/16" 10 10 26.4 243/4" 13 3/16" 13 13 33.0 301" 15 1/4" 15 15 38.5 35

OFW Welding Tip InformationOFW Welding Tip Information

3434


BRAZING TIP SELECTION CHART

Thickness Tip Diameter of Oxygen Acetylene Oxygen Acetyleneof Metal Size Brazing Rod Pressure Pressure Consumption Consumption

In Inches Number In Inches (P.S.I.G.) (P.S.I.G.) (SCFH) (SCFH)

1/64" 0 ---- 1 1 2.2 21/32" 1 ---- 1 1 3.3 33/64" 2 1/16" 2 2 4.4 41/16" 3 1/16" 3 3 5.5 53/32" 4 3/32" 4 4 6.6 61/8" 5 3/32" 5 5 8.8 83/16" 6 1/8" 6 6 11.0 101/4" 7 1/8" 7 7 14.3 135/16" 8 5/32" 8 8 17.6 163/8" 9 5/32" 9 9 22.0 201/2" 10 3/16" 10 10 26.4 24

OFB Brazing Tip InformationOFB Brazing Tip Information

3535


16GA Gas Air Adapter with Soldering Tip (Together)16GA Gas Air Adapter with Soldering Tip (Together)

16GA Gas Air Adapter with Soldering Tip (Separated)16GA Gas Air Adapter with Soldering Tip (Separated)

½” – 20 Threads½” – 20 Threads

Air-Fuel Soldering TipsAir-Fuel Soldering Tips

3636


SOLDERING TIP SELECTION CHART

Thickness Tip Diameter of Acetylene Acetyleneof Metal Size Soldering Wire Pressure Consumption

In Inches Number In Inches (P.S.I.G.) (SCFH)

1/64" 1 1/16" 2 1.51/32" 1 1/16" 2 1.53/64" 2 1/16" 4 21/16" 2 1/16" 4 33/32" 3 3/32" 6 41/8" 3 3/32" 6 5

Air-Fuel Soldering Tip InformationAir-Fuel Soldering Tip Information


Oxyfuel Gas CuttingOxyfuel Gas Cutting

Cutting Attachments, Cutting Attachments, Cutting Torches, & TipsCutting Torches, & Tips

3838


OxygenOxygenCutting LeverCutting Lever

AcetyleneAcetyleneCutting ValveCutting Valve

MixerMixer

Cutting TipCutting Tip Union NutUnion Nut

Oxygen ValveOxygen Valve

Acetylene Acetylene ValveValve

OFC Hand Cutting TorchesOFC Hand Cutting Torches

Combination Torch with Cutting AttachmentCombination Torch with Cutting Attachment

3939


CUTTING TIP SELECTION CHART

Thickness Tip Cutting Oxygen Acetylene Oxygen Acetyleneof Metal Size Orifice Pressure Pressure Consumption Consumption

in Inches Number Drill Size (P.S.I.G.) (P.S.I.G.) (SCFH) (SCFH)Light gauge

to 3/16 000 #68 15-20 5-15 35-40 10-153/16 - 3/8 00 #64 20-25 5-15 45-50 10-153/8 - 5/8 0 #60 35-40 5-15 75-85 15-20

5/8-1 1 #56 35-40 5-15 97-107 15-201-2 2 #52 40-45 5-15 180-195 20-302-3 3 #48 45-50 5-15 270-290 20-353-6 4 #42 50-75 10-15 450-600 25-40

OFC Cutting Tip Information OFC Cutting Tip Information

4040


6290-G Gouging Tip6290-G Gouging Tip

GougingGouging

OFC Torch Specialty TipsOFC Torch Specialty Tips

4141


6290-R Rivet Cutting Tip6290-R Rivet Cutting Tip

Rivet CuttingRivet Cutting


Tie Down CuttingTie Down Cutting

4242


6290-RW Rivet Washing Tip6290-RW Rivet Washing TipRivet WashingRivet Washing


4343


6290-2D Thin Sheet Cutting Tip6290-2D Thin Sheet Cutting TipThin Sheet CuttingThin Sheet Cutting



Oxyfuel Gas HeatingOxyfuel Gas Heating

Heating Assemblies, Heating Assemblies, Tubes & Tips Tubes & Tips

4545


HEATING ASSEMBLIES, TUBES and TIPS Selection Chart

H-63 2290-H 2290-HPMTip Tip Tip Oxygen Acetylene Oxygen AcetyleneSize Size Size Pressure Pressure Consumption Consumption

Number Number Number (P.S.I.G.) (P.S.I.G.) (SCFH) (SCFH)

1 1 1 10 4 160 4025 12 320 80

2 2 2 15 7 220 5545 22 520 130

3 3 3 25 8 340 8570 25 920 230

4 4 4 50 10 640 160110 30 1300 325

5 5 5 60 14 720 180135 40 1600 400

Heating Tubes & Tips InformationHeating Tubes & Tips Information



Peripheral EquipmentPeripheral Equipment

4747


Check Valves for RegulatorsCheck Valves for Regulators

Check Valve for the TorchCheck Valve for the Torch

Check ValvesCheck Valves

4848


Open Oxygen Check ValveOpen Oxygen Check Valve Closed Oxygen Check ValveClosed Oxygen Check Valve

Normal Normal Gas FlowGas Flow

Oxygen Check ValveOxygen Check Valve

4949


Open Acetylene Check ValveOpen Acetylene Check Valve Closed Acetylene Check ValveClosed Acetylene Check ValveNormal Normal

Gas FlowGas Flow

Acetylene Check ValveAcetylene Check Valve

5050


Dirty Oxygen Check ValveDirty Oxygen Check Valve Dirty Acetylene Check ValveDirty Acetylene Check Valve


Dirty Check ValvesDirty Check Valves

5151


Flashback Arresters for RegulatorsFlashback Arresters for Regulators

Flashback Arresters for TorchesFlashback Arresters for Torches

Flashback ArrestorsFlashback Arrestors

5252


Flashback Arrestor Flashback Arrestor OxygenOxygen

Flashback ArrestorFlashback ArrestorAcetyleneAcetylene



Check ValveCheck Valve

Flame Flame BarrierBarrier

Thermal Thermal Cut OffCut Off

Normal FlowNormal Flow

5353


Flashback ArrestorFlashback ArrestorOxygen Reverse FlowOxygen Reverse Flow

Built In Built In Check Valve Check Valve

Stops Stops Reverse Flow Reverse Flow

of Gas(es)of Gas(es)



Flashback Arrestor Flashback Arrestor Acetylene Reverse FlowAcetylene Reverse Flow

Reverse Reverse Gas FlowGas Flow

Reverse FlowReverse Flow

5454


Flashback Flame Flashback Flame Quenched at the Quenched at the

Flame BarrierFlame Barrier



Flashback Arrestor Flashback Arrestor Oxygen FlashbackOxygen Flashback

Flashback Arrestor Flashback Arrestor Acetylene FlashbackAcetylene Flashback

FLASHBAC FLASHBAC OCCURINGOCCURING

FlashbackFlashback

5555


Quick Connectors for RegulatorsQuick Connectors for Regulators

Quick Connectors for TorchesQuick Connectors for Torches

Quick ConnectorsQuick Connectors

5656


Red (Acetylene) Hose Nuts Red (Acetylene) Hose Nuts Have Left-Handed ThreadsHave Left-Handed Threads

““T” Grade Hose Required for all Fuels Except AcetyleneT” Grade Hose Required for all Fuels Except Acetylene

Green (Oxygen) Hose Nuts Green (Oxygen) Hose Nuts Have Right-Handed ThreadsHave Right-Handed Threads

HosesHoses

5757


Acetylene (Red) Hose Nuts Acetylene (Red) Hose Nuts Have Left-Handed ThreadsHave Left-Handed Threads

Oxygen (Green) Hose Nuts Oxygen (Green) Hose Nuts Have Right-Handed ThreadsHave Right-Handed Threads

Hose NutsHose Nuts

5858


PRESSURE DROPS IN NOMINAL HOSE SIZES FOR OFW

Possible Pressure Drop is given in Pounds per Square Inch (PSI)

Hose Up to 25 25 - 50 50 - 75 75 - 100Diameters Feet Feet Feet Feet

3/16 Inch 0.5 1.0 1.4 1.81/4 inch - - 0.3 0.5 0.85/16 inch - - - - 0.2 0.43/8 inch - - - - - - - -

OFW Pressure Drop in HosesOFW Pressure Drop in Hoses

5959


PRESSURE DROPS IN NOMINAL HOSE SIZES FOR OFC

Possible Pressure Drop is given in Pounds per Square Inch (PSI)

Hose Up to 25 25 - 50 50 - 75 75 - 100Diameters Feet Feet Feet Feet

3/16 Inch 2.6 4.2 6.8 10.61/4 inch - - - - 2.2 3.45/16 inch - - - - - - - -3/8 inch - - - - - - - -

OFC Pressure Drop in HosesOFC Pressure Drop in Hoses

6060


Tank WrenchTank Wrench

Tee WrenchTee Wrench

Tank WrenchesTank Wrenches

6161


Flint LighterFlint Lighter

6262


One PieceOne Piece

Tip CleanerTip Cleaner

Two PieceTwo Piece

1 copyright 2004 lincoln global inc. oxyfuel gas welding & cutting principles of the processes

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