MEC 101

Basic Mechanical Engineering

Unit 2 -MANUFACTURING TECHNOLOGY

(FOUNDRY & WELDING)
Dr. N. Sathiya Narayanan
Assistant Professor-III
School of Mechanical Engineering
SASTRA Deemed University

Unit 2-Manufacturing Technology (Foundry & Welding) 1

Unit 2-Manufacturing Technology (Foundry & Welding)

⁂Foundry
⁂Pattern Making (Single Piece, Split Pieces and Core)

⁂Casting
⁂Preparation of Green Sand Mould
⁂Pouring of Molten Metal
⁂Fettling and Cleaning
Unit 2-Manufacturing Technology (Foundry & Welding) 2
Unit 2-Manufacturing Technology (Foundry & Welding)
※Welding
※Principles
※Types
※Manual Metal Arc Welding
※Oxy-Acetylene Gas Welding
Unit 2-Manufacturing Technology (Foundry & Welding) 3
 Classification of Manufacturing

• Machining (All Cutting operations)- Divisibility

• Rolling, Forging, Extrusion- Ductility or Malleability

• Sheet metal working- Plasticity

• Casting, Welding- Fusibility

Unit 2-Manufacturing Technology (Foundry & Welding) 4

Source: [Link] & [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 5

 Foundry
• A foundry is a place/workshop/industry that produces castings.

• Metals/alloys are cast into desired shapes by melting them into liquid form.

• By providing a degree of super-heat under controlled atmospheres, and then

pouring the liquid metal in a mould cavity and allowing it to solidify.

• The solidified material may be used in the as-cast form with some degree of
machining or might be subjected to additional working/processing to obtain the
desired shape/size/ geometry/ dimensions of the component.

Unit 2-Manufacturing Technology (Foundry & Welding) 6

 Pattern
• It’s a tool used to produce mould cavity.

• The shape of the pattern is the same as that of the component, but the size

will be slightly larger than the component required. Why?

• Also referred as positive replica of the required component.

• ‘N’ Number of components can be made with single pattern.

Unit 2-Manufacturing Technology (Foundry & Welding) 7
Source: [Link] & [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 8

 Pattern Materials
⁘Commonly used for making patterns for sand moulding,
⁘ Can be easily shaped or worked with to get patterns of
desired shape and size.
⁘Light in weight, abundantly available, cheap and can be
handled easily.
⁘However, wood is easily affected by moisture, and it
possesses less strength. Hence, it is not suitable for mass
production.
⁘The most common types of wood used are mahogany,
teak and pine.
Source: Basic Mechanical Engineering by G. Shanmugam S. Ravindran ([Link])

Unit 2-Manufacturing Technology (Foundry & Welding) 9

 Pattern Materials
‡ Metal patterns are mostly cast from wooden patterns or
machined to desired shape.
‡ Metal patterns are stronger, accurate and durable. Ability to
withstand rough handling, high resistance to warp, wear and
abrasion.
‡ However, metal patterns are expensive and not easily repaired.
Ferrous metals get rusted.
‡ Metals are heavier and difficult to handle and cannot be
machined easily. Metal patterns are used when the number of
castings to be manufactured is large.
‡ Aluminium and its alloys, steel, cast iron, brass and white metal
are the different metals used for making patterns.
Source: Basic Mechanical Engineering by G. Shanmugam S. Ravindran ([Link])

Unit 2-Manufacturing Technology (Foundry & Welding) 10

Pattern Materials
❖ Plastic patterns are prepared with the help of wooden
patterns.
❖ Plastics are light, moisture resistant and provide a smooth
surface, wear and corrosion resistant.
❖ Plastic patterns are durable and do not involve any
appreciable change in size or shape.
❖ However, plastic patterns are weak and need metal
reinforcement for light sections.
❖ Plastic patterns are also not suited for machine moulding.
❖ Both the thermosetting and the thermoplastic materials are
used for making patterns.
❖ Common plastic materials used for making patterns are
epoxy resin, polyester resins and polystyrene.
Source: Basic Mechanical Engineering by G. Shanmugam S. Ravindran ([Link])

Unit 2-Manufacturing Technology (Foundry & Welding) 11

 Pattern Materials
¤ Plaster pattern is also made with the help of
wooden patterns.
¤ Plaster pattern can be easily worked by using
wood working tools. Intricate shapes can be
made easily.
¤ Plaster has a high compressive strength. Hence,
the plaster pattern is used for making small and
intricate castings and core boxes.
¤ Materials such as plaster of Paris or gypsum
cement are commonly used for plaster patterns.
Source: Basic Mechanical Engineering by G. Shanmugam S. Ravindran ([Link])

Unit 2-Manufacturing Technology (Foundry & Welding) 12

Pattern Materials
⁒ The wax pattern is made in a water cooled
metal mould or a die.
⁒ The wax pattern provides a very good
surface finish and high accuracy.
⁒ For removing the wax pattern, the mould
with the pattern is inverted and heated to
make the wax melt away.
⁒ The wax pattern is used in investment
casting or lost wax process.

Source: Basic Mechanical Engineering by G. Shanmugam S. Ravindran ([Link])

Unit 2-Manufacturing Technology (Foundry & Welding) 13

Selection of Pattern Materials
• Number of Castings required.
1) Wood

• Nature of moulding process.

2) Metal

• Desired Accuracy in the casting

3) Wax

** Casting refers to the

4) Plaster
Component**

Unit 2-Manufacturing Technology (Foundry & Welding) 14

Sand molding Tools – Quiz Time

15
Riddle
Sand molding Tools Rammer
Shovel

Strike-off bar Draw spike

Slick

Vent wire Flask

Lifter Sprue

Trowel
Swab
16
 Hand Riddle
o -Used for cleaning the moulding sand.
o -Removing the foreign materials such as nails,
shot metals, splinters of wood etc.

Shovel
❖ Used for mixing, tempering and conditioning
the foundry sand by hand.
❖ Also used for moving and transforming the
sand to the container or moulding box.
Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 17
 a)Hand rammer
o Made of wood or metal.
o Small in size, one end carries wedge shape called peen,
another end cylindrical in shape.
o Used for bench moulding
b) Peen rammer
Used in packing the sand in pockets and corners

Sprue pin
❑ Tapered rod of wood or iron
❑ To provide passage for molten metal in cope
Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 18
 Strike off bar
• Made of wood or iron
• Used to strike off or remove the excess sand from the top of
the moulding box

Mallet
o Similar wooden hammer
o Used to drive draw spike into the pattern for removing,
rapping and withdrawal from the mould

Draw spike
➢ Used to withdraw the pattern from the mould
Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 19
 Vent rod -To provide vent holes

Trowels
o used for finishing the flat surfaces, joints and parting
line of the mould.

Slicks
o Small double ended finishing tool
o Repairing and finishing the surfaces and edges of the
mould
Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 20
 Bellows
-To blow away the loose sand from the mould surfaces
and cavities

Swab
-Used for swooping away the sand
-Used for coating the liquid on dry sand mould surfaces

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 21
Sand molding Tools

22
 Moulding Boxes or Moulding Flasks

Open type

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 23
 Types of Patterns
✓Single piece pattern ✓Loose piece pattern

✓Split piece pattern ✓Gated pattern

✓Match plate pattern ✓Skeleton pattern

✓Shell pattern
✓Cope and drag pattern
✓Follow board pattern
✓Sweep pattern

Unit 2-Manufacturing Technology (Foundry & Welding) 24

 Single piece pattern (or) Solid pattern
o This is the simplest type of pattern, exactly like the desired casting in terms of
shape/geometry.
o For making a mould, the pattern is accommodated either in cope or drag.

Source: [Link] & [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 25
 Split pattern (or) Two-piece pattern
※ These patterns are split along the parting plane to
facilitate the extraction of the pattern out of the mould
before the pouring operation.
※ For a more complex casting, the pattern may be split in
more than two parts.
※ The upper and lower parts of the slit piece patterns are
accommodated in the cope and drag portions of the
mould, respectively.
※ Dowel pins are used for aligning the parts.
Source: [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 26

 Match plate pattern
⁂ A match plate pattern is a split pattern having the
cope and drags portions mounted on opposite sides of
a plate (usually metallic), called the "match plate"
that confirms to the contour of the parting surface.
⁂ The gates and runners are also mounted on the match
plate, so that very little hand work is required. This
results in higher productivity.
⁂ This type of pattern is used for a large number
of castings.
Source: [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 27

Types of Patterns - Video
Source: [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 28

 Sand Casting Process Video
Source: [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 29

Elements of Gating System

Source: [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 30

 Core
⁘ It is inserted into the mold cavity prior to pouring
⁘ The molten metal flows and solidifies between the mold cavity and the core to form the casting's
external and internal surfaces
⁘ May require supports to hold it in position in the mold cavity during pouring, called chaplets

(a) Core held in place in the mold cavity by chaplets,

(b) possible chaplet design, (c) casting with internal cavity.

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 31
 Properties of Sand
⁘ Refractoriness- Ability of withstanding high temperatures
⁘ Cohesiveness -Ability of particles to stick together.
⁘ Collapsibility - Ability of the sand mixture to collapse under force.
⁘ Adhesiveness- Attachment of particles to another body viz., box
⁘ Grain size and shape
⁘ Flowability/Plasticity - Ability to get shaped to desired forms/patterns
⁘ Porosity or Permeability - To facilitate escape of gases mould

Unit 2-Manufacturing Technology (Foundry & Welding) 32

 Types of Moulding Sand

1. Green sand 5. Facing sand

2. Dry sand 6. Backing sand

3. Loam sand 7. Core sand

4. Parting sand

Unit 2-Manufacturing Technology (Foundry & Welding) 33

Source: [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 34

 Sand Moulding
Green Sand Molding Dry Sand Molding
¤ The mold is prepared by green sand
• This process is similar to the
and pouring is done in a sand mold
Greensand mold expect the
with sand in its green or natural state
composition of sand.
is known as Green Sand Molding.
• The composition is different from
¤ For producing green sand, the
green sand. For preparing dry sand the
mixture is prepared consisting of
special types of the binder are used
Silica sand, Clay 10 to 15 %
such as resin, clay or molasses for
(Bentonite), Moisture 4 to 6 %.
producing a strong bond
Unit 2-Manufacturing Technology (Foundry & Welding) 35
Source: [Link]
 Loam Sand
• Loam sand is sand containing up to 50
% clay which has been worked to the
consistency of builder mortar. Used
for loam sand moulds for making very
heavy castings.

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 36
 Parting Sand
• This sand is used during the making of the mould to
ensure that green sand does not stick to the pattern
and the cope and drag parts can be easily
separated for removing the pattern without causing
any damage to the mould.

• The parting compounds used include charcoal,

ground bone and limestone, groundnut shells, talc
and calcium phosphate.
Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 37
 Facing Sand
• Facing sand is the sand which covers the pattern all around it.
The remaining box is filled with ordinary floor sand. Facing
sand forms the face of the mould and comes in direct contact
with the molten metal when it is poured.

• High strength and refractoriness are required for this sand. It

is made of silica sand and clay without the addition of any
used sand.

• Graphite may be added to the facing sand. The thickness of

the sand layer varies from 20 to 30 mm.
Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 38
 Backing Sand
• Backing sand is the bulk of the sand used to back up the facing

sand and to fill up the volume of the flask (cope & drag).

• It consists mainly of old, repeatedly used moulding sand which is

generally black in color due to addition of coal dust and burning

on contact with hot metal.

• Due of the color backing sand is also sometimes called black

sand. The main purpose for the use of backing sand is to reduce

the cost of moulding.

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 39
 Core Sand
• Core sand is the sand used for making cores.

• Silica sand mixed with core oil.

• The core oil consists of linseed oil, resin and light

mineral oil with some binders.

• For larger cores, sometimes pitch or flour and

water may also be used to save on cost.

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 40
 Quiz Time
• Cohesiveness ?
• Flowability ?
• Refractoriness ?
• The sand does not stick to the pattern and the cope and drag
parts can be easily separated for removing the pattern
without causing any damage to the mould. Name of the sand?
• Facing sand purpose?
• What is backing sand and why its in black colour?
• Whats the purpose of chaplets and whats the material?
• Runner and riser difference.
Unit 2-Manufacturing Technology (Foundry & Welding) 41
Quiz Time

42
Preparation of Green Sand Mould

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 43
Unit 2-Manufacturing Technology (Foundry & Welding) 44
Unit 2-Manufacturing Technology (Foundry & Welding) 45
 Melting Furnaces
• All metals and alloys are converted to liquid state using an equipment called
furnace.

• Provides/Acts as a heat source for the conversion of solid to liquid.

• Furnaces are to be selected based on

• Type of metal to be melted

• Quantity of metal to be melted

• Fuel used.

Unit 2-Manufacturing Technology (Foundry & Welding) 46

 Furnaces
⁘Crucible Furnaces (30-150kg)
⁘Cupola Furnaces (1ton –15ton)
⁘Electric arc Furnaces
⁘Induction arc Furnaces

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 47
 Fettling process
• Fettling process addresses the conversion of a rough casting into a more
refined product for a good appearance.

• Fettling includes
o Removal of cores from the casting

o Removal of adhering sand and oxide scale from the casting surface

o Removal of gates, risers, runners

Source: [Link] &

[Link] Unit 2-Manufacturing Technology (Foundry & Welding) 48
 Fettling process (Removal of cores from the casting)
• Core removal might be difficult in the absence of suitable equipment.

• Hammering or vibrations to be imparted to loose and break the cores.

• Metal rods are used to remove the sand portions sticks inside the castings by
poking action.

• Pneumatic rapping and hydro blasting are considered for the removal of cores
from the larger castings.

• Depending on the size of the component, the above tool(s) may be brought to
the component or vice-versa.
Source: [Link] &
[Link] Unit 2-Manufacturing Technology (Foundry & Welding) 49
 Fettling process

Source: [Link] & [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 50
 Fettling process
• Removal of adhering sand and oxide scale from the casting surface.
• Removal of Gates and risers
⁜Chipping hammers.
⁜Flogging.
⁜Shearing.
⁜Sawing.
⁜Abrasive wheel slitting.
⁜Machining.
⁜Flame cutting.
Source: [Link] &
[Link] Unit 2-Manufacturing Technology (Foundry & Welding) 51
 Cleaning process

Shot blasting Tumbling Cast Vs After finishing product

Source: [Link] &
[Link] Unit 2-Manufacturing Technology (Foundry & Welding) 52
 Cleaning process
Buffing
o Buffing is defined as a finishing process that involves the use of a loose abrasive on a
wheel.
o To polish a workpiece, a manufacturing company may use a wheel that’s covered with
an abrasive disc.
o The loose abrasive on the disc essentially removes superficial material and
imperfections, thereby creating a smoother surface.
Polishing
o Polishing, on the other hand, is a finishing process that involves the use of an abrasive
that’s secured — typically with glue or other adhesives — to the wheel.
o As a result, polishing is considered a more aggressive finishing process when compared
to buffing.
Unit 2-Manufacturing Technology (Foundry & Welding) 53
Source: [Link]
 Temporary Vs Permanent Joining

1. Mechanical joining by means of bolts, screws and rivets

2. Adhesive bonding by employing synthetic glues such as

epoxy resins

3. Welding, brazing and soldering

Unit 2-Manufacturing Technology (Foundry & Welding) 54

Unit 2-Manufacturing Technology (Foundry & Welding)
※Welding
※Principles
※Types
※Manual Metal Arc Welding
※Oxy-Acetylene Gas Welding
Unit 2-Manufacturing Technology (Foundry & Welding) 55
 WELDING - Principle
• Welding is a material joining process that produces coalescence(joining) of

materials by heating them to suitable temperatures with or without the

application of pressure or by the application of pressure alone, and with or

without the use of filler material.

• Welding is used for making permanent joints.

• It is used in the manufacture of automobile bodies, aircraft frames, railway

wagons, machine frames, structural works, tanks, furniture, boilers, general repair

work and shipbuilding. Unit 2-Manufacturing Technology (Foundry & Welding) 56

 TYPES OF WELDING
Plastic Welding or Pressure Welding

The piece of metal to be joined are heated to a plastic state and forced
together by external pressure

Fusion Welding or Non-Pressure Welding

The material at the joint is heated to a molten state and allowed to

solidify.

Ex: Arc welding, Gas welding

Unit 2-Manufacturing Technology (Foundry & Welding) 57

Arc welding - Video

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 58
 Arc welding
Equipment:
• Gloves
•A welding generator (D.C.) or
Transformer (A.C.) • Wire brush
• Two cables- one for work and one for
electrode • Chipping hammer

• Electrode holder
• Goggles
• Electrode
• Protective shield

Unit 2-Manufacturing Technology (Foundry & Welding) 59

 Arc welding

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 60
 Arc Welding Equipments

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 61
Shielded Metal Arc welding (SMAW)
 Working Principle of MMAW
• An arc is a sustained electric discharge through the ionized gas column called Plasma between
two electrodes.

• Electrons liberated from the cathode move towards the anode and accelerate their movement.
When they strike an anode at a high velocity, a large amount of heat is generated.

• During travel, they collide ions in the ionised gas column between electrodes. The positively
charged ions moving from an anode would impinge on the cathode, thus liberating heat.

• About 70% of heat is generated at the anode by electron striking. A temp of 6000 C was
generated at the anode. The potential difference between the electrodes should be sufficient to
allow them to move across the air gap
Unit 2-Manufacturing Technology (Foundry & Welding) 63
 MMAW/SMAW Working
o Based on the principle that when an electric current is passed through an air
gap from one electric conductor to another, an electric arc is produced
[Generates very intense and concentrated heat - 3500 °C to 4000 °C -
melts a small portion of metal in the workpiece]
o The electric arc keeps this molten metal pool agitated and the base metal is
thoroughly mixed with melted electrode metal.
o The metal pool cools down under a protective cover of slag left by the
electrode. On cooling, a strong weld joint is formed between the two metal
pieces 64
Source: [Link]
 MMAW/SMAW Working
o The length of the air gap (distance between the electrode tip and the work-piece
surface) is about 3 mm to 6 mm.
o The welding creates an electric arc between the electrode and the workpiece.
o Electric arc welding can use either DC supply or AC supply and a consumable or
non-consumable electrode.

Source: [Link] 65
 Comparison of A.C. and D.C. arc welding
Alternating Current Direct Current
(from Transformer) (from Generator)
• More efficiency • Less efficiency
• Power consumption less • Power consumption more
• Cost of equipment is more
• Cost of equipment is less
• Low voltage – safer operation
• Higher voltage – hence not safe
• Suitable for both ferrous non-
• Not suitable for welding non-ferrous ferrous metals
metals • Preferred for welding thin sections
• Not preferred for welding thin sections • Positive terminal connected to the
• Any terminal can be connected to the work
work or electrode • Negative terminal connected to the
electrode
66
 ELECTRODES
• Two types – Consumable and Non-consumable.

• In the welding process, once the arc is initiated, the electrode is

continuously consumed, and it should be moved towards the w/p to
maintain a constant arc length.

• Consumable electrode – a function of providing a filler metal and heat

are built into a single electrode. Steel, CI, Cu, Brass, Br, Al

• Non-consumable – Carbon(DC), Graphite(DC) or Tungsten(AC & DC).

Unit 2-Manufacturing Technology (Foundry & Welding) 67
 Filler Rods and fluxes

❑ Filler rods are used when an additional filler metal is required

in the weld area they come in different diameters.

❑ Fluxes protect the weld pool from contamination by oxygen

and nitrogen, they are normally in paste form and placed on a

heated filler rod before welding begins

Unit 2-Manufacturing Technology (Foundry & Welding) 68
Advantages Limitations
• Most efficient way to join • Manually applied, therefore high
metals
labor cost.
• Lowest-cost joining method
• Need high energy causing danger
• Affords lighter weight
through better utilization of • Not convenient for disassembly.
materials • Defects are hard to detect at
• Joins all commercial metals joints.
• Provides design flexibility
Unit 2-Manufacturing Technology (Foundry & Welding) 69
 Types of Joints

Unit 2-Manufacturing Technology (Foundry & Welding) 70

Source: [Link]
 Direction of Welding

Source: [Link]
between-forehand-welding-and-backhand-welding/

Unit 2-Manufacturing Technology (Foundry & Welding) 71

 Gas Welding
(Oxy-Acetylene)

Unit 2-Manufacturing Technology (Foundry & Welding) 72

 Gas Welding - Video
(Source: [Link]

73
 Gas Welding (Oxy-acetylene)
✓ Welding processes use a flame produced by burning a mixture of fuel
gas (acetylene) and oxygen.

✓Separate cylinders and a hose pipe from

each cylinder transport the gases to a torch.

✓Gas and fuel mix in the torch burns @

3100°C.

Source: [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 74

 Gas Welding-Principle
•During the welding, heat from the flame is
concentrated on the joint edges until the metal
melts and starts to flow.
•Filler Metal is fed in by hand into the weld
pool, at regular intervals where it becomes
molten and joins with the parent metal.

Source: [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 75

 Equipment used in Oxy-Acetylene welding
❑ The oxygen and acetylene hose pipes

❑ Gases cylinders

❑ Gas pressure regulators

❑ Flashback arrestor

❑ Welding torch/Welding nozzle

❑ Filler rods and fluxes

Unit 2-Manufacturing Technology (Foundry & Welding) 76
 Gases used
• Oxygen is extracted from the air and compressed into cylinders at high pressure

and the cylinder is black in colour.

• Acetylene (C2H2) is a fuel gas. Cannot be compressed directly as explodes at

high pressures. Cylinders are packed with a porous material that is filled with

acetone. Acetone absorbs acetylene. Cylinder in maroon colour.

Unit 2-Manufacturing Technology (Foundry & Welding) 77

Gas Pressure Regulators Welding torch
• One gauge indicates the • Oxygen and acetylene are delivered to the torch by

pressure of the cylinder and the separate hoses. Each gas is controlled by a valve on

other indicates the pressure in the torch. The two gases mix in the torch and after

the supply pipe to the torch. they are ignited burn at the nozzle.

Source [Link] [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 78
 Flashback Arrestors

These are positioned on both the fuel gas and oxygen supply between
the hose and the regulator. Their purpose is to prevent the return of a
flame through the hose into the regulator.

Source [Link] [Link]

Unit 2-Manufacturing Technology (Foundry & Welding) 79
 Types of Flame
Reducing or Carburizing
Excess acetylene (0.9:1)
(Alloy steels and aluminium alloys)
Oxidizing
Excess oxygen (1.5:1)
(Brasses, Bronzes, copper)
Neutral
Equal acetylene & oxygen
(low carbon steel, mild steels).

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 80
Carburising Neutral Oxidising

Source: [Link]
Unit 2-Manufacturing Technology (Foundry & Welding) 81
 Heat Zones
❖ The oxy-acetylene flame has two distinct zones.

❖ The inner zone (Primary combustion Zone) is the hottest part of the flame.

❖ The welding should be performed so that the point of the inner zone should be just above the
joint edges.
C2H2 + O2 2CO + H2
Primary Combustion zone

Unit 2-Manufacturing Technology (Foundry & Welding) 82

 Heat Zones
o The outer zone the secondary combustion envelope performs two functions
o Preheats the joint edges
o Prevents oxidation by using some of the surrounding oxygen from the weld pool
for combustion and gives off carbon dioxide and water vapour

CO + H2 + O2 CO2 + H2O
Secondary Combustion zone

Unit 2-Manufacturing Technology (Foundry & Welding) 83

Advantages:

•It is easy to operate and does not require high skill operator.

•Equipment cost is low compare to other welding processes.

• Equipment is more portable than other types of welding.

•It can also be used as gas cutting.

Unit 2-Manufacturing Technology (Foundry & Welding) 84

Disadvantages

•It provides a low surface finish and needs a finishing operation after welding.

•Gas welding have large heat affected zone which can cause a change in

mechanical properties of the parent material.

•Higher safety issue due to naked flame of high temperature.

•It is Suitable only for soft and thin sheets. Slow metal joining rate.

Unit 2-Manufacturing Technology (Foundry & Welding) 85