Oxy-hydrogen gas as a sustainable fuel for the welding industry: Alternative for oxy-acetylene gas

Abstract

The urgent need to address climate change has prompted researchers to explore sustainable power generation methods using low or net-zero fuels and energy storage. Historically, gases derived from acetylene or LPG have been used for welding in factories. Despite its negative effects on the environment and human health, acetylene gas remains widely used. Examples of pollutants released from acetylene gas include carbon dioxide and carbon monoxide, both of which contribute to the greenhouse effect and global warming. There is a need for an alternative gas that is environmentally friendly, economically viable, and readily available. Hydrogen gas is currently used across various industries and is increasingly considered a potential primary fuel source for the future. In this study, a hydrogen fuel cell was used to produce HHO (brown) gas as a replacement for acetylene through electrolysis. The HHO gas was used to weld a randomly selected test piece, which was then evaluated alongside an acetylene-welded test piece. The integrity of both welds was assessed using dye-penetrant and radiographic testing, showing that welds from both gases were strong. Welding with HHO gas, followed by non-destructive inspection, also proved effective, with any defects attributed to inexperience in welding. The adoption of HHO gas in the welding industry is recommended due to its potential socio-economic benefits, health advantages, and environmental friendliness. Challenges related to initial investment costs may be mitigated as technology advances. Further research should focus on qualitative weld testing, economic and environmental impact assessments, and developing a business model for HHO systems.