Oxyfuel Operations Joining Cutting and Surfacing

Course Number: 118

This course covers the welding of ferrous and nonferrous metals. It describes oxygen cutting as well as brazing, soldering, and surfacing techniques.

Recommended Contact Hours - 8

Chapter 1: Welding Ferrous Metals

Topics: Fusion welding; Fluxes; Flame characteristics; Temperature control; Welding common mild steels, stainless steel, cast iron, and wrought iron

Learning Objectives:

• Explain how oxyfuel welding joins metals and how it differs from arc welding.
• Explain how braze welding and torch brazing are different from oxyfuel welding and from each other.
• Discuss the purposes for using flux and characteristics that make a flux suitable for an application.
• Compare the appearance and general uses of the carburizing flame, neutral flame, and oxidizing flame.
• Explain why preheating and postheating are used.
• List important considerations in welding common mild steels, stainless steel, and cast and wrought iron.

Chapter 2: Welding Nonferrous Metals

Topics: Joint preparation; Welding aluminum, copper, brass, bronze, lead, nickel, and magnesium

Learning Objectives:

• Discuss characteristics of aluminum that are important in welding.
• Explain how to use aluminum alloy designations.
• Describe procedures used in aluminum joint preparation and in aluminum welding.
• Discuss characteristics of copper and copper alloys that are important in welding.
• Discuss procedures for welding copper, brass, and bronze.
• Discuss procedures for welding lead, nickel, and magnesium.
• Summarize general standard procedures for making optimum welds.

Chapter 3: Oxygen Cutting

Topics: Oxygen cutting process, torch, and tips; Cutting safety; Cutting bevels; Piercing holes; Cutting circles; Removing rivets; Gouging; Scarfing

Learning Objectives:

• Explain the similarities and differences between oxyfuel cutting and oxyfuel welding.
• Describe the equipment and safety precautions necessary for torch cutting and list standard steps in the torch cutting operation.
• Describe special equipment or methods used in cutting bevels, piercing holes, cutting circles, and cutting away rivets.
• Explain why gouging, scarfing, and washing are used.
• Explain methods used on metals that are otherwise difficult to cut.

Chapter 4: Brazing and Soldering

Topics: Filler alloys and fluxes; Brazing and braze welding cast, malleable iron, aluminum, and steel; Safety; Soldering; Kinds of solder; Soldering tools

Learning Objectives:

• Compare and contrast brazing, braze welding, and oxyfuel fusion welding.
• Describe the materials and procedures used in brazing and braze welding.
• Explain important special considerations in braze welding cast and malleable iron, brazing aluminum, and brazing stainless steel.
• List the safety precautions necessary for brazing and braze welding operations.
• Explain how soldering differs from brazing and describe the materials and procedures used in soldering.

Chapter 5: Surfacing Techniques

Topics: Thermal spraying; Hard facing; Flame spraying; Surfacing materials; Preparation; Safety

Learning Objectives:

• Define hard face welding and thermal spraying as used for surfacing purposes and discuss general uses of each.
• Discuss advantages and disadvantages of detonation-gun, plasma, and electric arc thermal spraying and explain how each is done.
• Describe the processes of torch hard facing and flame spraying.
• Name several common surfacing materials and discuss one or more characteristics of each.
• List the steps, including those for surface preparation, in repairing a shaft by means of thermal spraying.
• Discuss the safety precautions necessary to prevent or minimize hazards from surfacing processes.