See channel playlists for full-length
HD video features available at the
Mechanix HD Video Network...Click channel buttons for
Join 4WD Mechanix Magazine at
'How-to' Welding Class: Improve and Test Your Gas Welding
This HD video introduces the five practice exercises
that you will find on the click links (below). If you have sufficient bandwidth, each of
these HD videos can be view in 1080P quality and 'full-screen' size!
See the five additional HD
video links listed for practice exercises and insights that can improve your oxy-acetylene gas welding
skills! Begin with the tack welding demonstration...
Quick Guide to five HD video gas welding
As these final exercises demonstrate, gas welding can provide the strength, fusion quality and
base metal compatibility found with other welding processes. Gas welding still serves some types of pressure vessel
work, high pressure pipe repairs and other niche tasks.
Gas welding has been
around for over a century now. The process lends itself to niche uses, like auto body work, tubing and fitting
tasks, industrial tool repairs and small parts restoration. Unlike brazing, oxy-acetylene welding is a bona fide
metal fusion process.
As the filler tube
holder project illustrates, gas welds can resemble MIG or TIG welds. Above is a bead run with oxy-acetylene process
and ER70-S2 filler rod. Strong and reliable, this weld matches the integrity of any other fusion welding
There are lessons in gas welding that apply to
all other forms of fusion welding. Although the rush is to MIG or TIG machines, those who take the time to
study and practice oxy-acetylene gas welding will be well rewarded. Gas welding is the first type of welding
taught in traditional welding schools and classes. Oxy-acetylene welding is a valued foundation
tube rack (above) is a product of gas welding. This project took less than an hour to complete,
converting a catalog rack into a functional holder for Weld Mold Company's filler rod
canisters.As seen in the illustrations
below, gas welding process can produce very strong welds, with results similar to other fusion welding
Note: These Weld Mold Company filler
rod tubes are very handy, keeping the filler rods dry and preventing surface oxidation of the rods. Cardboard
construction is flammable, however, and getting the tubes off the shop floor and away from the welding area was
wise. An old parts catalog rack looked like a good base for a tube holder—and also provided the practical gas
welding project seen here!
For those following
the 'How-to: Welding Class' coverage of gas welding and brazing
processes, the sub-pages in this section
containuseful practice exercises for gas
welding. Take the time to view these HD videos,
they offer insights that apply to every
kindof fusion welding.
The catalog stand had wings at each end. Turned into craddle
flanges, the "wings" are positioned for tack welding. Paint removed from the weld joint, tack
welding can now begin.
Caution: The painted rack is older, and the paint could
contain lead or zinc. Ventilation is necessary to keep fumes away from the welding hood. Use a fan and respirator
with air filters if necessary.
The two wings get tack welded into
position as with any other welding process. With this gauge metal, we use ER70-S2 in 3/32" diameter. In the HD
videos covering gas welding exercises (see sub-pages to this page), you can watch the
welding process in real time!
welds at each end of the wing will support the wing as we run
thewelding bead. This is
similar to stick, MIG or TIG tack welds. ER70-S2 filler rod material has
83K PSI tensile and 70K shear or yield strength.
welding filler material dips into the molten weld puddle, similar to TIG process. Gas torch with a #2 tip
heats the metal evenly to the liquid point. Filler melts upon hitting the liquid puddle. (See
practice exercises for a demonstration in real time.)
Finish beads are both strong and equal in
stamina to MIG, stick or TIG. Gas welding is slower but very functional for smaller parts and even field service
work. The only downside is the diffused heat pouring into the metal, which tends to create a wider heat affected
Yes, this is actually a gas welded bead!
The formation looks much like MIG, with full fusion of the metal parts and buildup of filler metal in a uniform
crown. The canister holder is now painted and ready for service.
What appears to be a "weld bead" here is
actually the backside of the weld! Yes, the pentration is that good in this case. The weld has a normal crown (on
opposite side) that provides exceptional strength and a deep weld joint. Back side "weld" is in part due to the
intentional, slight gap placed between the two pieces prior to welding.