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How To Weld 3D Printed Parts

CNC-controlled electron beam welding achieved the locational accuracy and deep penetration needed to weld together four separate 3D printed aluminum heat exchanger sections into a single assembly that is the heart of the HVAC prototype system.
The 3D metal printing process is prone to capture microscopic inclusions and voids in the material. When these parts are welded, these micro voids coagulate into large bubbles of porosity that weaken the weld due to stress concentration in the area of the porosity. John DeLalio of EB Industries explains how electron beam welding can be used to address this issue.

Intelligent Bending

Frames are fabricated from 30 mm diameter steel tubing in up to two-meter lengths. Because the frame parts are bent very accurately with precision placement of the various bolt fixing holes, the tubes are swaged prior to bending and the holes are punched afterwards on a separate machine. The tube orientation station in the cell ensures that frames are bent in such a manner that holes are never punched through tube weld seams.
This plant heralded a complete shift to all-electric tube bending technology to meet huge demand for their new product with an integrated tube processing system that merges robotic handling of the material to bend extremely long tubing in very short cycle times and almost double their manufacturing output from 1,800 units to 3,500 units a day.

Welding Abrasion-Resistant Plate: Three Common Challenges and Their Solutions

Specifically designed for long service life in the harsh conditions of mining or quarrying, earthmoving and construction, the incredibly high hardness of AR plates is ideal for protecting critical components from excessive wear caused by frequent impact and/or sliding contact with abrasive materials, such as backhoe buckets and teeth, bulldozer blades and dump truck beds.
Here are some tips that make it easier to avoid cracks and prevent lost time and money when welding these incredibly hard plates.

Closing the Loop: Strategies for Bending Closed Forms

This custom press brake tool consists of a pair of upper tool holders, connected by a bar, to create a large window. The bar attaches to one of the tool holders by a pivoting hinge, and the other end is held in place by a magnetic clasp. This tool allows a closed profile to be formed around the bar and then removed by releasing the magnetic clasp, pivoting the bar outward, and easily sliding the finished product free of the tool assembly. (first view)
With a bit of creativity and thought to overcome limitations, it is often possible to form closed profiles and other difficult parts with a standard press brake. Here are some tips on how to do it.

The Importance of Proper Welding Operator Training

The weld pool in different processes may look different. For this reason, operators should be trained on “reading” the weld pool for the process at hand. There is no substitute for practice.
To gain more business in the face of a skilled labor shortage, fabrication shops need welding operators that are familiar with a wider variety of welding processes and materials and can take on new jobs to set their shops apart. Proper operator training plays a key role in reaching these goals.

What You Need to Know Right Now to Improve High-Volume Micro Manufacturing

This newest 20-80xD solid carbide micro drill has come in handy for many manufacturers looking to replace time-consuming EDM operations with micro drilling in their machining center while the part is fixtured for additional operations.
Opportunities abound for shops to cash in on the ever-growing micro machining market, but the differences between different types of micro tools vary from those found in standard tooling. Here are some insights into the extra care and know-how needed to achieve success and build a successful reputation as a reliable supplier of micro machined parts.

The Largest Qualified 3D Metal Part for European Aerospace is Here

3D printed by powder-bed-based laser melting, Europe’s largest additively manufactured part in orbit is an antenna support for satellites made of aluminum with dimensions of 447 x 204.5 x 391 mm3, excluding the height of build plate. (first view)
How do you economically produce huge parts with intricate geometry that has a tendency to warp but must withstand critical applications in a demanding environment? Here’s the answer.

How Clean is Clean Enough? Evaluating Air Quality

Visible dust on surfaces is a key indicator of air quality problems. If your processes generate a consistent amount of particulate at all times, it may be enough to take a few “snapshot” readings and average the result. But if your processes are variable, a unit that takes incremental measurements will identify both “peak” measurements and total particulate exposure over a period of time to see how air quality changes as your industrial processes cycle.
Is your shop clean enough to fabricate components for medical devices? A proper diagnosis is necessary to solving an OSHA or FDA particulate problem. But before installing an air quality remedy, it helps to know your current particulate levels, exposure profile and airflow patterns. Let’s take a closer look at this evaluation process.

AGT Robotics is First ESAB Automation Partner in North America

The ESAB Integrator Partnership Program, which has proven successful in Europe and is now expanding  to North America, combines expertise in automation equipment and filler metals with the engineering of custom systems for a total  solution that maximizes productivity and quality.
These partners now offer custom turnkey automated welding and cutting systems, along with service and support throughout Canada and the U.S.

Advanced Measurement Technologies

Booth E-5532: The compact, powerful AVR300 CNC general-purpose bench top video-based vision system from Starrett are ideal for quality assurance, inspection labs, manufacturing, assembly and research facilities. (first view)
These powerful, high precision CNC vision systems and optical comparators from Starrett increase inspection productivity, speed and accuracy, even on difficult to measure complex parts.