Intro to Oxy-Acetylene Welding - Part 2
Summary
TLDRThe video provides a step-by-step guide on using a filler rod for welding, demonstrating the process of joining two pieces of metal. It begins with the setup of the welding torch, tacking the metal pieces together, and explaining the 'circle dip' technique for adding filler material. The instructor emphasizes the importance of heat control, penetration, and safety precautions throughout. After testing the weld's strength with a hammer, adjustments are made to improve the technique. The video concludes with tips on purging the gas valves and offers practical advice for beginners, especially students learning welding basics.
Takeaways
- 💡 Fusion welding relies solely on melting metal together without extra material.
- 🛠️ Filler rod welding adds additional metal, enhancing strength and filling gaps.
- 🔥 Adjust the flame properly by managing acetylene and oxygen levels for efficient welding.
- ⚠️ Bend the filler rod to remember which end is cold and safe to handle.
- 🔄 The 'circle dip' technique involves creating a molten puddle, then adding filler material in a circular motion.
- 👓 Always wear gloves and safety glasses while welding to avoid burns and accidents.
- ❌ Insufficient heat and filler material can result in weak, surface-level welds with poor penetration.
- 🔧 Increasing heat and making wider, slower welds improves penetration and strength.
- 🔨 Test welds with a hammer to evaluate strength—more penetration creates stronger bonds.
- 🧯 After welding, turn off and purge the acetylene and oxygen valves to safely shut down the equipment.
Q & A
What is the main focus of this welding tutorial?
-The main focus is demonstrating how to weld using a filler rod, in contrast to fusion welding where only the metal is melted together. This technique is used to fill gaps and add strength to the weld.
Why does the instructor find using a filler rod easier?
-The instructor finds using a filler rod easier because it helps to get the puddle started and provides more control during the welding process.
What safety precaution does the instructor highlight regarding the filler rod?
-The instructor emphasizes the importance of distinguishing between the cold and hot ends of the filler rod by adding a bend to one end, ensuring that the user knows which end is safe to handle.
What technique does the instructor use when welding with the filler rod?
-The instructor uses a 'circle dip' technique, where they move the torch in a circular motion while intermittently dipping the filler rod into the molten puddle to add material as they progress.
Why does the instructor heat the metal before adding the filler rod?
-The instructor heats the metal to ensure that it reaches the molten state before adding the filler rod. This guarantees that the metal is properly melting and not just the filler rod.
What does the instructor observe about the first weld after testing its strength?
-The instructor observes that the first weld had very little penetration and was primarily a surface weld, which broke easily under minimal force.
How does the instructor improve the second weld?
-The instructor increases the heat and makes wider, slower welds to ensure better penetration of the metal, resulting in a stronger weld.
What tool does the instructor use to test the weld strength, and what were the results?
-The instructor uses an 8-pound sledgehammer to test the weld strength. The weld held up much better than the first attempt, showing increased strength even when hit from both sides.
What does the instructor recommend doing after finishing the welding process?
-After finishing welding, the instructor recommends purging the valves, closing the acetylene and oxygen valves, and ensuring the equipment is safely turned off. They also advise cleaning up and practicing regularly.
What is the target audience for this welding tutorial?
-The tutorial is intended for introductory-level students in grades 8 to 12, as specified by the instructor.
Outlines
🔥 Introduction to Using Filler Rod in Welding
This paragraph introduces the topic of using a filler rod for welding, as opposed to fusion welding. The speaker explains that adding filler metal can help fill gaps, provide additional strength, and make the process easier to control. The speaker starts by describing how to light the torch, adjust the flame, and perform a tack weld using a filler rod. They also emphasize heating the metal sufficiently before applying the filler, ensuring a good bond. The speaker gives tips like bending the filler rod to identify the hot and cold ends, ensuring safety while handling it during welding.
🔧 Demonstrating the Welding Process
In this section, the speaker walks through the actual welding process. They explain the technique of 'circle dip,' where the filler rod is dipped into the molten metal in a circular motion while moving forward. As they demonstrate, they adjust the acetylene and oxygen levels for optimal flame and review the results of the weld. After completing a weld, the speaker examines the quality, noting that while the weld appears good on the surface, it lacks proper penetration. This leads to the conclusion that more heat is needed for a stronger bond.
⚒️ Improving Weld Strength and Testing
The speaker decides to redo the weld, this time increasing the heat and widening the weld to improve metal penetration. They emphasize taking it slow to allow the metal to melt properly. After completing the weld, the speaker tests the strength by clamping the piece in a vise and striking it with a hammer. This time, the weld holds much better, though some bending occurs. The speaker decides to test further by using an 8-pound sledgehammer, which also shows that the weld is strong enough for practical purposes, though the metal does bend slightly.
🔌 Shutting Down and Recap of Welding
The final paragraph covers the process of safely shutting down the welding equipment. The speaker explains how to purge the valves, close the acetylene and oxygen regulators, and ensure that no gas remains in the system. After explaining the procedure for purging the valves, the speaker advises cleaning up the workspace and practicing welding regularly. In conclusion, the speaker clarifies that this approach is used in their welding classes for students in grades 8 to 12, and while it may not be industry standard, it works effectively at the introductory level.
Mindmap
Keywords
💡Filler rod
💡Puddle
💡Tack weld
💡Penetration
💡Acetylene
💡Oxygen
💡Circular motion
💡Safety glasses
💡Hammer test
💡Flashback
Highlights
Introduction of filler rod welding, adding metal for more strength and gap filling compared to fusion welding.
Explaining the technique of starting the puddle before adding filler material to ensure proper melting of the base metal.
Instructor demonstrates tack welding with the filler rod, explaining the importance of preheating before applying the rod.
Instructor explains the use of a bent filler rod to differentiate between the cold and hot ends, emphasizing safety.
Describing the 'circle dip' method used during the welding process for controlled application of the filler rod.
Detailed explanation of flame adjustment: balancing acetylene and oxygen for optimal flame control and metal heating.
Initial weld inspection reveals a surface weld with insufficient penetration, requiring increased heat and gap adjustment.
Discussion on adjusting technique for better weld strength, including increasing heat and using larger welds for deeper penetration.
Reminder about adjusting grip on the filler rod to prevent fingers from getting too close to hot metal.
Weld inspection shows improved penetration but still not optimal strength, prompting further adjustments.
Demonstrating a stress test with a hammer, revealing a stronger weld but still highlighting areas for improvement.
Final stress test with an 8-pound sledgehammer, showing the weld holding well under increased force, though slightly bending.
Step-by-step process for safely shutting down the welding setup, including purging acetylene and oxygen valves.
Instructor's final advice: clean up the workspace and practice welding regularly for skill improvement.
Instructor clarifies that the techniques shown are for introductory level grades 8-12 and may not match industry standards.
Transcripts
[Music]
[Music]
the next forum of Walden that we're
going to be doing is using filler rod to
weld these two together so the first one
was just fusion welding letting the
metal itself melt together this one
we're going to be adding a little bit of
metal to it to fill in our gaps maybe
give it a little bit more strength a
little bit more material in there I find
this is actually easier to get my puddle
started at in control let's do this so
once again light your torch just a
little bit I want a nice little flame
I'm going to increase the pressure till
it's feathered again
add my oxygen I'm gonna do my tack weld
with my filler rod by heating the two up
together get it almost a puddle I like
to get this nice and hot before just
sticking the coal rod on top of there
just a quick tack I do the same thing to
the other end before it expands or
contracts so evenly between the two
pieces you know it's getting kind of hot
they can tell us about to the molten
long gonna throw a little bit of filler
rod in there just enough to hold it
together this one's not for strength now
I'm ready to run might be here now then
so just quickly before I do this my
filler rod here I'm just using a very
thin one I've got two ends to this one
here and one here if you notice I've
added a bend to it I do that so I
remember which is the cold end and which
is the hot end so my cold ends so I
always know that if I grab here I'm
gonna be mostly safe unless this thing
is only of three inches long and this
end I'm gonna assume that it's hot
don't go touch it don't go lick it
please all right let's get back to
welding I'm gonna be wearing my gloves
I'm gonna be holding it like this with
my torch I'm probably gonna be doing a
very small circular motion and dipping
this into the puddle kind of as I go
forward so you'll see me circle dip
circle dip circle dip circle dip all the
way along where I want my weld to be
light it increase your acetylene until
it's feathered that's black smoke goes
away increase your oxygen until you have
that nice little cone and that's well
heat this up until it gets molten and
then we're gonna start adding our filler
material so I want to get that puddle
started before I add the filler material
cuz I really want to make sure that the
metal is melting not just my rod here we
go
puddles starting I'm going to do circle
dip circle dip circle and dip I get a
little bit more of a puddle going there
and just kind of circle dip maybe every
one or two circles let's go forward
I'm gonna stop there and we can take a
look at it
acetylene and then oxygen so if I look
closely at that I see I have a very nice
little I have a nice weld on top it's
gonna be strong enough I can flip it
over and see how the penetration is
again maybe not enough penetration I
think I'm gonna have to add more heat
let's continue this with some more heat
so again let's get our puddle started
I'm just gonna continue from where we
left off and remember that your filler
rod is gonna get shorter the longer you
well just be aware of where you're
holding it okay puddle has started you
need a couple circle dip Circle dip
Circle dip my filler rod sometimes goes
in between the flame in the metal that
kind of pre eats it and then lets it
drip into that little puddle there we go
much nicer I've increased the heat or it
I increase the pressure is working
lovely
that's settling off oxygen off it's not
a bad weld I'm a little bit rusty on
this I don't do this as often since I've
been using a MIG welder but I think this
is going to be strong enough let's clamp
into a vise and smack it with a hammer
and see how it holds up don't forget
your safety glasses and be careful you
don't hit your hand on this hot metal so
what does that tell me I look very
closely at it it broke off with very
little effort I got very little
penetration and it was mostly just a
surface weld so that tells me that I
need to have a bit more of a gap and add
more heat to get through a piece of
metal like that
let's do it again
start with my tax just to hold it in
place
enough get it hot before you add your
tax just to hold it together there's not
gonna be any real strength there
all right let's heat this thing up I
turned up the heat I'm going to add some
bigger welds I'm gonna go a little bit
wider and really try to penetrate this
metal
circle dip circle dip I'm gonna take my
time really get that metal melted
through there this time
careful how close you are so you don't
get any kind of dip or flashback adjust
your grip on your filler rod now and
then to make sure you're not getting too
close to the metal with your fingers now
nice and slow nice big wide here
settling then oxygen to turn it off wait
for that's a cool for just a moment and
let's flip it over
lovely so we have a lot more penetration
coming through this one still not quite
enough to make it extremely strong but
it might hold up better than the last
one so if you look closely at that
there's a little bit more penetration
than there was before you can see it
more down on this side here not so much
this ones where we ended we have the
whole metal going really really hot do
not touch this this will blister a lot
let's put this over and take a quick
look at that that's a decent weld you
can tell that it's really curved into
the metal a little bit more kind of like
this like a scoop I could go over it
again if I wanted and add a bead on top
of that but let's see how strong this
one is it's clamped in let's grab our
hammer that's much stronger than the
first one let's hit it from both sides
so depending on its use this would be a
fine weld I think we need to go get a
bigger hammer so we got an 8 pound
sledge let's try that one now it is
bending a little bit but the weld is
still holding let's get a closer look at
that
not too bad it's still holding up pretty
good now just for fun let's just break
it so once we are done welding we need
to turn off this whole setup I'm going
to start by purging the valves so it's a
purge the valves I'm gonna close my
acetylene first close that till it's
tight I'm gonna roll back my regulator
the - or in this case counterclockwise
open my acetylene to make sure all the
gas is left the acetylene valve empty if
you look close that here it'll be
reading zero next oxygen turn it off all
the way clockwise good we want to get
this to be empty reading zero I'm going
to turn my valve back all the way
counterclockwise open my valve
and this should be going down to nothing
turn it off
wrap it up for everybody else put your
striker away clean up your mess and
practice everyday
so just to recap this is how I do it
with my classes this is not necessarily
industry standard but this is what works
well for us at a complete introductory
level from grades 8 to 12 have an
awesome day
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