One of the methods of joining metal elements is gas welding. What is the method and how to properly carry out the gas welding process? For which materials is gas welding the best method?
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What is gas welding?
Gas welding is a process of joining materials under the influence of heat generated by a gas torch flame. This creates a durable and strong weld. Gas welding uses equipment that allows for generating very high temperatures. The heat source is a burning gas torch, allowing for the mixing of gases in the right proportion.
The gas combustion process is a solution with many advantages. One of the most important is its versatility, because thanks to gas welding, materials such as steel and copper can be joined, and it is also suitable for joining non-ferrous metals, such as aluminum. The device itself used for welding is not large, so there is no difficulty in moving it.
It is also not dependent on power sources, so it can be used in various places. During the weld, the welder has the ability to precisely control the temperature of the filler metal, which is used to connect the elements.
How to weld using gas method accurately?
To effectively weld using the gas method, you will need welding tools and the appropriate skills. Welding using acetylene is a method that requires high precision and safety measures.
The most important thing is to prepare the equipment. You will need a gas tank, a burner, hoses and pressure regulators. Before starting the welding, you will need to prepare the material to be joined. The welding process will be effective if the surface is clean, there can be no contamination on the material, e.g. rust or grease stains. After thorough cleaning, you should additionally check the fit of the components. To make precise connections, it is worth using additional solutions, such as clamps or magnets.
After starting the torch, it is very important to properly adjust the torch flame, setting the desired flame size. It is very important to properly adjust the amount of acetylene burned, because the mixture cannot be too rich (reducing) or too lean (oxidizing). A skilled welder will easily recognize the optimal type of flame, which is blue and conical.
During gas welding, it is important to maintain the appropriate distance between the flame and the welded surface. This is crucial because the high temperature could damage the weld and cause leaks. If the flame is too close, there is a problem with excessive and uncontrolled melting of the welding material. However, if the distance is too large, it will be too weakly heated. The torch flame should be moved along the weld line, slowly, which ensures optimal coverage of the joint with the weld.
The welder makes a circular or zigzag movement, thanks to which the heat is distributed evenly. The additional material, which is the welding rod (wire), should be introduced in the place where the flame heats and melts the edges of the joined elements. It is very important here that the rod melts directly into the weld, causing it to fill.
When finishing the combustion process, it is very important to gradually turn off the burner, first closing the acetylene valve and only then the oxygen valve. The prepared weld should be left to cool down naturally, this process should not be accelerated, as it could negatively affect the properties, lead to cracking or deformation of the material. When checking the weld, first make a visual assessment, and then a strength assessment.
What materials are best for gas welding?
Gas welders are perfect for welding thin sheets. Heating with a flame created in the combustion process requires a lot of patience, it is a method in which the work of the burner cannot be accelerated. The joining of metals must be precise, performed in accordance with the rules of procedure.
Gas welding methods are suitable for joining only selected materials. They are used to make low-carbon alloys (mild steel), stainless steel, aluminum, copper and its alloys, nickel alloys, tool steel, magnesium and its alloys, zinc and its alloys. The gas welding technique also allows for welding cast iron, but due to the specific properties and thickness of the material, the welder must demonstrate great skills. Where it is not possible to use gas techniques, an inverter welder can also be used.