OxyAcetylene Cutting and Welding

In todays blog we are going to start exploring welding and the various processes one can use to join metal. I figure we should start at the beginning. The process that started our love affair with cutting, shaping and joining metal (in a modern way) is Oxygen-Acetylene. You’ve almost certainly seen it in videos, with the torches throwing crazy sparks.

We are going to talk about how it was discovered, and how it is used today.

Some History:

In the early 1900’s French engineers experimented with injecting pure oxygen into a fuel stream and combusting it. They found that by using forced oxygen, they could nearly double the temperature of a flame, and better pinpoint it. By developing cutting torches which control the oxygen-fuel mixture, the flame could be controlled to cut metal as well as join it. Acetylene was chosen, and became the predominant fuel because of its clean burn, high temperature and ease of control. In some industries propane or other fuels are still used, largely to reduce costs.

Starting in the 1920’s electric arc welding was being developed; however, the infrastructure of the time made it expensive and a specialized process. As a result through much of the 1960’s, Oxy-Acetylene welding was the predominant method of cutting or joining. Slowly, electric arc welding and cutting began to supersede oxygen-fuel processes, and today, it is rarely used in large scale production.

What are its Advantages Today:

Oxyacetylene is a Swiss Army knife process. It can cut, heat and weld, all with one setup. As a result, if there is only enough capital (or space) for one machine, a torch can be a great option. Many farmers, sailors and heavy equipment field repairmen rely on the fact that two tanks and a torch can fix almost any metal issue. The tanks can also be sized for any demand, meaning they can be more portable than any arc welder.

In that same vein, Oxyacetylene also does not require electricity for use. This makes it ideal for field repairs, or processes taking place in austere conditions. This can also be helpful for home shops, where the cost to run expensive electrical lines can prevent the installation of an electric arc welder. We’ve all seen the videos of 3rd world workers using these torches to carry out their daily tasks in dirt floor shops. The grid independence of oxyacetylene makes this possible.

The resultant flame is also neutral if tuned properly, meaning that it acts similar to a shielding gas. This means that a wider range of metals can be worked. Thermal spraying of coatings is only possible because of this neutral flame. It is also this fact that makes it usable in the glass and jewelry industries.

The process can be thought of as most similar to TIG welding, as it can both fuse metal and solder pieces. Soldering is critical in some industries, where thin materials are used which cannot be reliably fused. Since oxyacetylene works for both soldering and fusion welding, it can be tailored for each job at hand with relative ease.

What are the Downsides:

The main downside is that the process uses pressurized gases, not electricity. That means that the flame cannot be turned on and off with a single button like in electric arc welding. An open flame is exposed in the workshop both before and after the task at hand, which poses a significant safety risk. It can also be easy to overheat a part, as there isn’t a foot pedal or trigger to release. The only control is to remove the flame from the piece.

Since the process is burning gas, it also means that every second of flame time is using expensive consumables. Both Oxygen and Acetylene tanks are not cheap to refill, so excessive use can get costly, quickly. In addition, the excessive burning can release noxious fumes, which must be controlled.

Conclusion:

As you can see, oxyacetylene welding still has a place in our modern world. Its flexibility and unique characteristics earn a pair of tanks a spot in any metal shop. It is also critical to understand, it is not always the best for every job. Here at MFG Concepts, we pride ourselves in helping clients pick the best process for their needs.

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