Oxy-Acetylene Welding Course

Lesson 1 • Hazards of Oxy-Acetylene Systems

Covers fire, explosion, and asphyxiation risks specific to oxygen and acetylene gases. Builds the risk-awareness foundation required before any hands-on equipment contact.

Lesson 2 • Personal Protective Equipment

Identifies required PPE for oxy-acetylene welding and correct usage of each item. Proper protection prevents burns, eye damage, and respiratory injury.

Lesson 3 • Regulators, Hoses, and Fittings

Identifies regulator types, hose color codes, and fitting standards for oxy-acetylene systems. Correct assembly prevents leaks and ensures accurate pressure delivery.

Lesson 4 • Gas Cylinders and Storage

Teaches safe handling, transport, and storage of oxygen and acetylene cylinders. Correct storage prevents leaks, falls, and dangerous pressure buildup.

Lesson 1 • Lighting and Shutting Down the Torch

Teaches the correct sequence for lighting, adjusting, and extinguishing the torch safely. Improper sequencing causes backfires and dangerous gas accumulation.

Lesson 2 • Understanding Working Pressures

Explains gauge pressure, working pressure ranges, and acetylene pressure limits. Correct pressure settings are critical to flame stability and safe operation.

Lesson 3 • Flame Zones and Heat Distribution

Explains the inner cone, outer envelope, and feather of the flame and their temperature profiles. Positioning the inner cone correctly controls heat input and weld quality.

Lesson 1 • Fixturing and Distortion Control

Covers clamping, fixturing, and sequencing strategies to minimize thermal distortion. Controlling distortion during welding preserves dimensional accuracy of the finished part.

Lesson 2 • Surface Cleaning and Preparation

Teaches removal of mill scale, rust, paint, and contaminants before welding. Clean surfaces prevent porosity, inclusions, and poor fusion in the finished weld.

Lesson 3 • Identifying Common Base Metals

Covers identification of mild steel, cast iron, copper, brass, and aluminum by visual and spark tests. Metal type determines flame selection, filler rod, and technique.

Lesson 1 • Torch and Rod Manipulation Basics

Teaches grip, torch angle, travel direction, and filler rod feeding for forehand welding. Consistent manipulation produces uniform bead width and penetration.

Lesson 2 • Running Stringer Beads Without Filler

Practices fusion runs on flat plate to develop torch control before introducing filler rod. Autogenous runs reveal torch angle and speed errors without filler rod variables.

Lesson 3 • Adding Filler Rod to Stringer Beads

Introduces filler rod selection, dipping rhythm, and rod angle for flat stringer beads. Correct rod feeding prevents cold laps, porosity, and uneven reinforcement.

Lesson 4 • Flat Lap and T-Joint Welding

Extends flat welding skills to lap and T-joint configurations with fillet welds. Correct torch angle prevents undercutting the vertical member and ensures full fusion.

Lesson 1 • Overhead Welding Technique

Develops torch and rod control for overhead butt and fillet welds with reduced puddle size. Smaller puddles and faster travel prevent dripping and ensure adequate fusion.

Lesson 2 • Vertical Uphill Welding Technique

Teaches uphill progression for vertical butt and fillet welds with controlled puddle manipulation. Uphill travel provides better fusion and penetration on thicker materials.

Lesson 3 • Challenges of Out-of-Position Welding

Explains how gravity affects molten puddle control in vertical and overhead positions. Understanding these forces guides adjustments to flame size, speed, and rod technique.

Lesson 1 • Cutting Cast Iron and Non-Ferrous Metals

Explains why standard oxy-fuel cutting does not work on cast iron and non-ferrous metals. Alternative thermal cutting methods and flux-injection techniques are introduced.

Lesson 2 • Straight-Line Cutting on Flat Plate

Teaches guided straight cuts using a straightedge or track guide on mild steel plate. Consistent travel speed and torch angle produce a square, slag-free kerf.

Lesson 3 • Cutting Torch Setup and Operation

Covers cutting torch assembly, tip selection, and pressure settings for oxy-fuel cutting. Correct setup ensures a clean kerf and prevents tip clogging or backfire.

Lesson 4 • Shape and Template Cutting

Applies freehand and template-guided cutting to produce curved and irregular shapes. Template cutting develops torch control and prepares students for layout work.

Lesson 1 • Brazing Copper and Brass

Applies silver-alloy and bronze filler rods to braze copper tubing and brass fittings. Copper's high thermal conductivity requires careful heat distribution to avoid overheating.

Lesson 2 • Braze Welding Cast Iron

Teaches bronze filler rod technique for repairing cracks and joining cast iron components. Braze welding avoids the cracking risk associated with fusion welding cast iron.

Lesson 3 • Soft Soldering with the Torch

Covers torch-applied soft soldering for electrical and plumbing applications using tin-lead or lead-free alloys. Correct heat control prevents cold joints and component damage.

Lesson 4 • Flux Selection and Application

Covers flux types, application methods, and temperature activity ranges for brazing operations. Correct flux prevents oxidation and promotes filler flow into the joint.

Lesson 1 • Process Troubleshooting and Correction

Develops a systematic approach to diagnosing flame, pressure, and technique problems during welding. Structured troubleshooting reduces scrap and rework in production environments.

Lesson 2 • Common Weld Defects and Root Causes

Identifies porosity, cold lap, undercutting, burn-through, and cracking with their process causes. Linking defects to causes enables targeted corrective action rather than guesswork.

Lesson 3 • Visual Inspection Standards and Tools

Teaches visual inspection criteria, measurement tools, and acceptance standards for welds. Visual inspection is the first and most cost-effective quality control method.

Lesson 4 • Destructive Testing Methods

Covers bend tests, nick-break tests, and macro-etch examination for evaluating weld integrity. Destructive tests reveal internal defects not visible during surface inspection.