0.5 bar low-pressure gas welding — why Dillon is different
Conventional gas welding torches run higher pressure and produce a turbulent flame that scatters heat in all directions. Dillon is built for low pressure: 0.5 bar on both gases produces a soft, concentrated flame without turbulence — precision, control, and soft seams you can work.
See also: Gas welding with Dillon – the basicsDillon vs oxyacetylene
Want to try the 0.5 bar flame yourself? The Standard Kit suffices for most hobby users – the Pro Kit gives more tips and extensions.
What high-pressure gas welding gets wrong
Higher pressure gives higher gas velocity and a turbulent flame. Heat spreads uncontrollably, thin sheet deforms, and the joint becomes hard and difficult to work. Precision work in sensitive materials becomes risky.
Dillon's 0.5 bar system — why it works
Dillon's unique mixing chamber blends oxygen and acetylene at exactly the same low pressure — 0.5 bar. The gases flow laminarly without turbulence, the flame stays soft and extremely concentrated, and the heat stays where you point. The result: seams that are soft, stress-free and formable — you can hammer, file and planish them just like the original sheet.
Concrete advantages of 0.5 bar
Soft, concentrated flame
Laminar flow without turbulence — heat stays where you point it.
The sheet doesn't warp
Minimal heat spread gives stress-free seams even in 0.8 mm sheet.
Soft, workable seams
You can hammer, file and planish the joint — just like the original sheet.
Cheaper operation
Efficient combustion gives noticeably longer bottle life.
When 0.5 bar makes a difference
Thin sheet
Weld 0.8–1 mm sheet without deformation or burn-through.
Sensitive materials
Aluminium and cast iron demand precise heat control — Dillon delivers it.
Workable seams
Soft joints you can hammer and file — impossible with MIG or ordinary gas welding.
Getting started at 0.5 bar
1. Check your regulators
The regulators must work in the 0–1 bar range on both gases. If you already have gas welding equipment, your cylinders, regulators and hoses usually fit directly.
2. Set 0.5 bar and a neutral flame
Open both gases, set the pressure to 0.5 bar, light up and adjust to a neutral flame – blue core with no yellow tip.
3. Heat until a weld pool forms
Keep the flame moving and heat until a weld pool forms.
4. Add rod and weld forward
Feed the filler rod in front of the flame and move the flame in an even arc or zigzag. Smooth movements give soft, stress-free joints.
Where low-pressure gas welding makes the biggest difference
Thin sheet and bodywork
Stress-free seams even in 0.8 mm sheet – the seam can be hammered, filed and planished.
Aluminium and cast iron
Materials that demand precise heat control – with rod and flux.
Brazing, heating and cutting
The same torch brazes bronze and brass, heats seized nuts and cuts steel up to 25 mm.
Honestly: when MIG is better
For long seams in heavy structural steel on a production line, MIG is faster. Dillon is for the jobs in between.
Gas welding basics
Read how gas welding works, which gases you need and what you can do with Dillon.
Read the gas welding guideLow-pressure gas welding FAQ
What is low-pressure gas welding?
Gas welding with oxygen and acetylene where both gases run at low pressure. Dillon runs at 0.5 bar on both gases, which gives a soft, concentrated flame without turbulence.
Why does lower pressure give better control?
Lower pressure means lower gas velocity – up to four times lower than in a conventional torch. The gases flow laminarly, the flame is soft and the heat stays where you point it.
Which regulators do I need?
Regulators for both gases that work in the 0–1 bar range, since Dillon runs at 0.5 bar.
Does my existing gas welding equipment fit?
If you already have gas welding equipment, your cylinders, regulators and hoses fit directly, as long as the regulators work in the 0–1 bar range.
Is it cheaper to run?
Yes. Efficient combustion means the torch uses considerably less gas, so the bottles last noticeably longer.
Which materials can I weld at 0.5 bar?
Steel, stainless, aluminium, cast iron, cast aluminium, brass and copper. Dillon welds 8–10 mm and cuts 25 mm steel. Aluminium and cast iron need flux.
Do I need electricity?
No. Dillon runs entirely without electricity – you only need oxygen and acetylene.
Standard Kit or Pro Kit
Both kits run the same 0.5 bar system. Standard suffices for hobby, Pro gives more tips and accessories for professional work.
Learn more
Related guides
Gas welding with Dillon
Soft seams, runs without electricity, reaches materials MIG can't.
Standard or Pro?
Compare the kits and see which fits your needs.
Repair cast iron
Structural repairs with soft 0.5 bar flame and control.
Weld aluminum
Full penetration in 1 mm sheet without burning through.
Dillon vs ordinary gas welding
Softer flame, better control, workable seams.
The starter guide
Free guide to gases, pressure and your first seam.