Introduction to

Oxy-Acetylene Welding

Welcome to the Columbus Metal Shop!

The School of the Art Institutes
Columbus Metal Shop is one
of four Instructional Fabrication
shops at SAIC.
The Columbus Metal Shop is a
general access facility set up to
provide instruction and material
resources for the Schools
students, faculty, and staff.
The Metal Shops facilities and
unique instructional programs
have been structured to meet the
needs of students working on a
wide range of projects.

The metal shop facilities include a

wide range of hot and cold metal
working equipment.
providing instruction and technical
assistance to students and faculty
using the Schools shops and
fabrication facilities. Our staff work
collaboratively across artistic and
academic disciplines to support all
manners of fabricating art objects.

INSTRUCTIO
NAL
FABRICATIO
N

Instructional
Fabrications
mission is to
serve the
contemporary
art making
needs of the
School of the
Art Institute of
Chicago by

Instructional Fabrication is a
division within the department of
Instructional Resources & Facilities
Management (IRFM).

Cold working
capabilities include

drilling
punching
mechanical fastening
roll forming
bending

shearing
cutting
grinding
sanding

abrasive blasting

Instructional Fabrication

|3

Table of Contents
10
Mater
ial
Conce
rns

11
Mater
ial
Handl
ing

12
6
Getti
ng
Rea
dy

8
Equi
pme
nt
for
Proc
ess :
Che
ck
Out
Fro
m
Cag
e

Weldi
ng
Anato
my &
Capab
ility

14
Turni
ng on
Fuel

16
Turni
ng on
Fuel
contin
ued

18
Proce
ss :
Weldi
ng

20
Proces
s:
Cuttin
g

22
Closin
g
Down
:
Leavi
ng
Statio
n

Intr
odu
ctio
n to

Ox
yAc
etyl
ene
We

ldi
ng
OxyAcetyle
ne,
umumn
ya
dikenal
sebagai
oxyfuel,
merupa
kan
salah
satu
proses
pengela
san
tertua,
meskip
un
dalam
beberap
a tahun
terakhir,
telah
menjadi
kurang
populer
di
aplikasi
industri.
Namun,
masih
banyak
digunak
an
untuk
berbaga

i
aplikasi
.
peralata
n oxyfuel
adalah
serbagu
na,
pinjam
an itu
sendiri
untuk
pengela
san,
mematr
i,
menger
askanlas,
solder
perak,
pemana
san
logam (
membe
ntuk)
dan
memot
ong
oxyfuel.
Buku
ini
akan
menyor
oti
proses
pengela
san dan
pemoto
ngan

4|

The School of the Art Institute of

Chicago Instructional Fabrication

|5

G
Authoriza
tions
In order to
work in the
Metal Shop,
you must
first attend
an
Authorizatio
n.
Authorizatio
n Sign Up
Sheets and
Authorizatio
n Request
Forms are
posted
adjacent to
the tool
checkout
area in the
Columbus
Wood Shop,
Room 024.
It is highly
recommend
ed that new
patrons
complete
the
Introduction
to Metal
Working
Authorizatio
n before
participating
in the
welding
authorizatio
ns.

Planni
ng
Your
Project
(See also
Material
Concerns,
page 10)

We
encoura
ge
patrons
to speak
with the
shops
staff
about
making
material
choices
that best
suit your
projects
before
committi
ng to a
purchas
eyour
choice of
material
s may
limit
what
equipme
nt will be
available
to you.

A
P
Flammabl
e
Combusti
bles
Prohibited

S
t
w
i

Flammable
Liquids are
prohibited in
the Metal
Shop,
including
but not
limited to
butane
lighters,
propane,
aerosol
cans, and
solvents.
Use
extreme
caution
when
working
near
flammable
materials
(sketchbook
s,
backpacks,
etcetera).
Flames,
sparks, and
hot surfaces
can cause
fires.

R
e

H
T
i

S
C
h

P
C
h
C
u

S
S
t

6|

The School of the Art Institute of

Chicago Instructional Fabrication

|7

Equi
pme
nt
For
Proc
ess:
Che
ck
out
from
cage

Overview

R
E

Hearing Protection
W
e

Welding
Gloves

Striker

Eye Protection
R
E

Ear Muffs

Welding Jacket

Hand Protection

Weldin
g
Jacket

Weldin
g Tip or
Cutting
Attach
ment

Filler
Materi
al

Magnet
ic
Clamps
&
Fixture
s

L
o

R
recommended for persons with
r
e
is equipped with an exhaust
system
that must be activated before
using
welding equipment.

8|

The School of the Art Institute of

Chicago Instructional Fabrication

|9

S
l
Respirator

Material Concerns

The Columbus Metal Shop sells steel in a variety of

shapes and dimensions. Rod stock and tubing is
available in rounds and squares, angle iron is
available in a variety of dimensions, and sheet
metal is available in common gauges (thickness).
Linear material is sold by the foot length or in some
cases full lengths averaging 12 feet. Sheet metal is
sold by the square foot, with a minimum purchase
requirement of 4 square feet (24 X 24).

Handling

MaterialMaterial
e
l
d
i
n
g

Cold Rolled

Handling

How to Carry
A separate pair of gloves
for material handling is
recommendedDO NOT
use Welding Gloves. Also,
it is very important for your
welding gloves to remain
oil-free.

Types of Steel
Hot Rolled
Grayscale on surface

C
l
e
a
n
w
i
t
h
w
i
r
e
b
r
u
s
h
b
e
f
o
r
e
w

Use caution when

entering & exiting
doorways or blind
intersections.

Do not try to carry long

lengths or heavy material
without help. Avoid walking
in front of or behind
materials, walk alongside.
Shiny, oily surface

Clean with orange soap and paper

towels before welding. Dispose of paper
in red fire-proof can.

Before welding, make sure to remove all oil used

during the preparation and fabrication of materials.

DO NOT weld on materials, including hardware,

that contain:
Paint
Wax
Chrome Plated or
Galvanized Surfaces
Magnesium

Lead
Rust
Grease or Oil (burned oil is
a carcinogen)

Keep hand one hand-length

from end of material.

Reuse Bin

Recycle Bin

Material for the Reuse Bin must

be approved by management.

Please refrain from tossing

unusable material, recycle it.

10 |

Instructional Fabrication

The School of the Art Institute of Chicago

| 11

Welding: Anatomy & Capability

A.
Mixe
r

Barrel

Ther
e
are
8
mixi
ng
stati
ons
attac
hed
to
the
wall.
This
is
your
sour
ce
for
oxyg
en
and
acet
ylen
e
fuel.

The mixer
is where
you will
attach
welding
tips,

cutting
attach
ment,
and the
rosebu

C.
Cuttin
g
Attach
ment
The
cutting
attach
ment
simply
functio
ns as
a
conve
nient
and
econo
mical
appro
ach to
cutting
steel.
The
cutting
attach
ment
can be
used
for
materi
al up
to 3/4
of an
inch
thick.
d heating
torch.

Oxygen
Control
Valve

Mixing Chamber
Control Valve

Acetylene
Control
Valve

Acetylen
e Hose
(red)
Oxygen
Hose
(green)

Close up of
Cutting Attachment

Oxygen Control Attachment

ch
art.

B
The
re
are
3
typ
es
of
wel
din
g
tips
ava
ilab
le:
1,
3,
5,
and
9.
Tip
siz
e
will
dep
end
on
typ
e of
fille
r
mat
eria
l
use
d,
see
bel
ow

nt
tha
t
sh
oul
d
be
us
ed
wit
h
dis
cre
tio
n.
Ple
as
e
ch
ec
k
wit
h
sh
op
sta
ff
to
se
e if
it
mi
ght
be
rig
ht
for
yo
ur
pro
jec
t.

D
The
Ro
seb
ud
He
atin
g
Tip
is
use
d
for
spe
cifi
c
hea
ting
app
lica
tion
s.
The
Ro
seb
ud
is a
fuel
inte
nsi
ve
atta
ch
me

REGULATOR SETTINGS
Material

Tip Size

Acetylene

Oxygen

Filler Rod

22-18 gauge

8 psi

8 psi

1/16"

16-14 gauge

8 psi

8 psi

3/32"

12-10 gauge
1/4"-3/8"

8 psi

8 psi

1/8"

8 psi

8 psi

3/16" *

* 3/16" filler rod is not available through Resale.

12 |

Close up of
Rosebud Heating Tip

1.
Befor
e you
begin,
perfo
rm
Hover
Test.
P
l
a
c
e
t
h
e
b
a
c
k
o
f
y
o
u
r
b
a

9
Instructional Fabrication

The School of the Art Institute of Chicago

Tur
ning
On
Fuel

r
e
h
a
n
d
cl
o
s
e
t
o
a
w
o
r
k
s
u
rf
a
c
e
o
r
t
o
o
l
b
e
f
o
r
e
t
o
u
c
h
i
n
g

| 13

o
r
s
e
t
t
i
n
g
d
o
w
n
s
o
m
e
t
h
i
n
g
h
e
a
t
s
e
n
s
i
t
i
v
e
.
W
e
l
d
i
n
g
t

a
b
l
e
s
,
s
t
a
ti
o
n
a
r
y
e
q
u
i
p
m
e
n
t,
t
o
o
ls
,
a
n
d
s
c
r
a
p
m
a
t
e
ri
a
l
m
i
g
h
t
n

o
t
a
p
p
e
a
r
h
o
t
,
b
u
t
m
a
y
b
e
h
o
t
e
n
o
u
g
h
t
o
i
n
j
u
r
e
y
o
u
o
r
d

a
m
a
g
e
e
q
u
i
p
m
e
n
t.

2.
Take
enoug
h
hose
off
hange
r
caref
ully
s
o
t
h
e
m
ix
e
r
r
e
a
c
h
e
s
t
h
e
w
e

l
d
i
n
g
t
a
b
l
e
w
i
t
h
o
u
t
c
r
e
a
t
i
n
g
a
t
r
i
p
p
i
n
g
h
a
z
a
r
d
.

3.

Inspect the hose for wear or damage by

making your way from the torch handle to

the
reg
ulat
ors
.

4. Install
tip
into
mix
er,

hand
tight
en
nut
on
top
with
touc
h tip
facin
g to
the
left
(for
right
hand
use)
or
facin
g
right
(for
lefthand
use).

A
B

5. Check
torch
hand
le to

make
sure
it is
close
d by
gently
turnin
g
knobs

coun
ter
clock
wise
to
open
and
then
clock
wise
to
com
plete
ly
clos
e.

A
B

6. Check
regul
ator
keys

to
make
sure
they
are
backe
d out
(disen
gaged
) and
appro
ximate
ly
inch
of
thread
s are
expos
ed.

approxim
ately
inch

14 | The School of the Art Institute of Chicago

continue to next page
15

steps

Turning On
Fuel
continued

7.

Standing to the side of regulators,

acetylene shut-off valves slowly by turning counter-clockwise until
fully opened, then close

9.

Before the torch is lit, put on welding gloves and oxygenacetylene goggles.

Open:
Counterclockwise
1200

Close
turn:
Clockwise

8.

Open acetylene

1
0
0
0

1
8
0

while directing welding tip towards exhaust.

clock
wise
until 5
2
0
0

psi
regist
ers on
regula
tor
gauge
,
alway
s
readin
g in
red.
Then
close
mixer
valve.

200 1

1
0
0
0

1
8
0
2
0
0

Incr
eme
nts:
5
10,
Ac
15,
et
20
yl
en
e
N
u
m
be
r

Increments:
1, 2, 3, 4, 5
12000

1.0

15
10
5

30
psi

Light the
Torch

s
t
r
i
k
e
r
.

2.

Open
acetylene
control
valve on
mixer,
approxim
ately
1/8 turn
rotation
counterclockwise
.
spark!

3.

L
i
g
h

2.
0
kg/cm
2

proceed to lighting the torch

Process:
Welding

Direct
torch
away from
you,
towards
the
ventilation
.

25

0.5

1.

1.5

20

w
i
t
h

N
e
v
e
r
u
s
e
l
i
g
h
t
e
r
s
o
r
o
t
h
e
r
s
o

17

u
r
c
e
s

a
w
n

f
o
r

f
r
o
m

i
g
n
i
t
i
o
n
.

a
w
a
y

y
o
u
,
n
o
t
p
a
s
t
y
o
u
.

A
l
w
a
y
s
p
o
s
i
t
i
o
n
y
o
u
r
s
e
l
f
w
i
t
h
f
r
e
s
h
a
i
r
a
t
y
o
u
r
b
a
c
k
s
o
f
u
m
e
s
a
r
e
d
r

Adjust the
Flame
4. Adjust
acetylene to form
feather shaped
flame.

If there is
too much
acetylene,
flame
breaks away
from the tip.
Slowly add
oxygen
flame will
sharpen and
elongate.

Continue to add
oxygen

until neutral
flame is
established.

And Weld!
5.

Focus green
cone's
tip
(neutral
flame) onto
area you are
welding.

6.

Ma
int
ain
a
co
nsi
ste
nt
dist
an
ce
fro
m
ma
teri
al,
he
ati
ng
a
nar
ro
w
pat
h
bet
we
en
two
ma
teri
als.

7.

After puddle
is
established,
introduce
filler rod.

8.

Me
lt
fill
er
rod
int
o
pu
ddl

e
a
n
d

Flame Tip

m
o
v
e

ofWeld Direction <

a
l
o
n
g
,

Welding Tip
Filler Rod

e
s
t
a
b
l
i
s
h
i
n
g
a
w
e
l
d
p
a
t
h
,
o
f
t
e
n
c
a
l
l
e
d
a
b
e
a
d
.
Weld Path

18 |

The School of the Art Institute of Chicago

Fabrication |

Process:
Cutting
A.
Prepare
Equipmen
t
1.

Instructional

19

I
n
s
p
e
c
t
c
u
t
t
i
n
g
a
t
t
a
c
h
m
e
n
t
s

bef
ore
us
e.
If
the
re
ap
pe
ars
to
be
gre
as
e,
oil,
or
eq
uip
me
nt
da
ma
ge,
ret
urn
too
ls
to
the
ca
ge
an
d
ex
ch
an
ge
for
a
wo
rki
ng
rep
lac

e
m
e
n
t
.

h
a
n
dl
e
a
n
d
h
a
n
d
tig
ht
e
n
th
e
co
n
n
ec
tio
n
n
ut
.

2. I
n
s
e
r
t
c
u
t
t
i
n
g
a
t
t
a
c
h
m
e
n
t
i
n
t
o
t
h
e
t
o
r
c
h

3.

Adjust oxygen
regulator to the
pressure setting
relative
to
material
size, see
tip chart
below.
Then
open
oxygen
valve on
torch
handle.

4.

Ad
jus
t
ace
tyl
ene
reg

u
l
a
t
o
r

ch
ha
ndl
e.

t
o
1
0
REGU
LATO
R
SETTI
NGS

p
s
i
.
T
h
e
n
o
p
e
n
a
c
e
t
y
l
e
n
e
v
a
l
v
e
o
n
t
o
r

Material

Cutting Tip Size

Acetylene

Oxygen

Up to 10 gauge

000

8 psi

20 psi

Up to 3/16"

00

8 psi

20 psi

Up to 1/4"

8 psi

30 psi

Up to 3/8"

8 psi

35 psi

Up to 1/2"

8 psi

35 psi

Up to 5/8"

8 psi

40 psi

B. Ignite
Flame
1.

Open
acetylene
valve
on
1
torch /8 turn
and
light
with striker.

2. O
p
e
n
o
x
y
g
e
n
v
a
l
v
e
a
n
d
f
l
a
m
e
s
h
o
u
l
d

a
p
p
e
a
r
,
a
l
s
o
k
n
o
w
n
a
s
a
c
e
t
y
l
e
n
e
f
e
a
t
h
e
r
.
C
o
n
ti
n
u
e
t
o
a

d
d
o
x
y
g
e
n
a
n
d
r
e
d
u
c
e
f
e
a
t
h
e
r
u
n
t
i
l
n
e
u
t
r
a
l
f
l
a
m
e
i
s

e
s
t
a
b
li
s
h
e
d
.

3. E
s
t
a
b
l
i
s
h
p
u
d
d
l
e
b
y
m
a
i
n
t
a
i
n
i
n
g
a
c
o
n
s
i
s

t
e
n
t

m
e
a
s

d
i
s
t
a
n
c
e
f
r
o
m
m
a
t
e
r
i
a
l
,
h
e
a
t
i
n
g

w
e
l
d
i
n
g
)
.

4.

Depress
oxygen

lever

and move
make cut.

to

Cutting Attachment
Weld Cut

Direction of Cut >

Flame

Oxygen Lever

a
n
a
r
r
o
w
p
a
t
h
(
s
a

NOTES: Material must be

supported and cut with the
grain of the table, never
against.
Keep feet and hose from under
the table and away from falling
metal debris.

20 |

The School of the Art Institute of Chicago

Fabrication |

Repeat for
oxygen.

Closing
Down:
Leaving
Station

1.

Extinguish flame by first closing oxygen at mixer.

Turn torch handle knob counter-clockwise.
A
process to
close
Acetylene
acetylene
first, B
then oxygen.
at mixer.

2.

Instructional

21

Oxygen first,

Close shut-off valves

turning clockwise.

Close:
Clockwi
se

3.

Bleed the line. Open acetylene at mixer and allow fuel to

empty for a few seconds, a process known as bleeding the

line. Then
close
acetylene at
mixer.

4.

Back out regulator keys

regulators, exposing approximately

approximately inch

5.

Take tip off, be careful of temperature.

attachment to cool before returning to cage!

HOT!

6.

22 |

Hang hose up on wall rack in large, neat loops. Return

all the equipment back to the cage.

The School of the Art Institute of Chicago

Fabrication |

23

Instructional

End Comments
Please do not hesitate to ask for help. If you are not absolutely certain
about what you are doing, or if you are having difficulty with any
aspect of the process we can help.
If the equipment is not working properly or appears to be
damaged stop immediately and seek shop staff.

General Principles in Welding Steel

A well balanced neutral flame is used for welding most steels. To be sure
the flame is not oxidizing, it is sometimes used with a slight acetylene
feather. A very slight excess of acetylene may be used for welding alloys
with a high carbon, chromium, or nickel content. However, increased
welding speeds are possible by using a slightly reduced flame. Avoid
excessive gas pressure because
it gives a harsh flame. This often results in cold shuts or laps, and
makes molten metal control difficult.
The tip size and volume of flame used should be sufficient to reduce the
metal to a fully molten state and to produce complete joint penetration.
Care should be taken to avoid the formation of molten metal drip heads
from the bottom of the joint. The flame should bring joint edges to the
fusion point ahead of the puddle as the weld progresses.

The pool of the molten metal should progress evenly down the seam
as the weld is being made.
The inner cone tip of the flame should not be permitted to come in contact
with the welding rod, molten puddle, or base metal. The flame should be
manipulated so that the molten metal is protected from the atmosphere by
the envelope or outer flame.
The end of the welding rod should be melted by placing it in the puddle
under the protection of the enveloping flame. The rod should not be
melted above the puddle and allowed to drip into it.

INSTRUCTIONAL
FABRICATION