Welding

Material joining by the use of power sources, gases, nozzles, tips, wire, filler metals, manual and automated processes, robots, jigs, turntables, consumables and other equipment assisted by Computer Aided Design (CAD), Computer Aided Manufacturing (CAM) and Computer Numerical Control (CNC).

How to Improve Robotic Welding Production

Here are four key strategies that will help welding managers, particularly those new to the job, keep their shops competitive by increasing their production while keeping costs low and quality on par.
Experts
Automation/Robotics

Robotic Welding Productivity: Touch and Go

The human-machine interface allows operators to control, monitor and collect data from the system with a simple touchscreen on a hand-held device that provides a realistic view of the robotic welding systems, from operating trends to productivity tracking, along with crucial alerts for troubleshooting should operational issues occur during the welding process.
The interaction between the operator and a robotic welding system can be improved by centralizing operations into one user interface.
Engine Driven Welders

The Lowdown on Welding Power Sources

MIG welding of high-horsepower wheeled tractor components in the Jackson, MN facility of AGCO Corporation. Two primary factors that determine output power are material thickness and the diameter of the wire or electrode used for welding.(Click on photo to enlarge it)
Jeff Herb of Miller Electric explains why no welding power source solution can fit all needs, then shows how an understanding of your application, your future needs and your environment will help you pick the right power source.
Filler Metals/Electrodes

Understanding the Basics of Low-Hydrogen Stick Electrodes

When welding in the flat and horizontal positions, point/drag the electrode 5 deg to 15 deg away from the direction of travel to help reduce the chance of trapping slag in the weld. The weld bead width should usually be two and half times the diameter of the electrode’s core wire for flat and horizontal welds.
Knowing the basics about E7018 low-hydrogen stick electrodes can be helpful in understanding how to maximize their operation, their performance and the welds they can produce.
Fume Extraction Systems

New Technology Expands Work Envelope When Using Fume Extractors

 Air is suctioned into the arm at a standard fume capture rate of around 900 cfm, while simultaneously, clean filtered air moves out of the arm at about a 90 deg angle to the unfiltered air coming in. This creates an “air barrier” that basically increases the effective diameter of the hood on the end of the arm. 
Source capture is the recommended method of  fume extraction because it removes contaminated air at the source, before it reaches a welder’s breathing zone. Recent advancements in source capture technology create a much larger capture area than what’s available with existing systems and can minimize how often the welder has to move the extraction arm.
Gases

Clearing the Air in Gas Delivery

With a clearer understanding of the gas delivery systems that are currently available, shops should be better equipped to select the correct gas handling system for your application.
MIG and TIG welding, plasma cutting, laser cutting or welding all require compressed gases. How these gases are stored, handled and used will determine the extent that the overall cost of these gas products impacts your bottom line. The correct gas delivery system will provide the most economical and efficient results to complement any of these applications – and the normal starting point for all of them is a cylinder of gas and a regulator. 
Inverter Welders

Field of Dreams

High Tech Welding has gained 25 to 30 percent in productivity in its field repairs since it began using the Multimatic 200 a year ago. The portability and multiprocess capabilities of the unit are at the heart of those benefits.
Take a look at how this Wisconsin fabricator uses the portable all-in-one Multimatic 200 multiprocess power source from Miller Electric to gain versatility and increase their welding productivity by 25 to 30 percent on field repair and fabrication jobs.
Laser Welders

Laser Beam Delivery and Focusing Optics

For lasers of a certain wavelength, around 1 micron (corresponding to neodymium-doped yttrium aluminum garnet (Nd:YAG), fiber and diode), the laser can be delivered to the workstation by a flexible fiber optic cable. This offers great convenience for integration because the flexible fiber can be routed by whichever orientation is best for the system.
Some tips and best practices for maintaining a high production yield in micro welding.
MIG Welders

New Arc Process for More Efficient Welding

Cross-section of a root weld seam welded with LSC Root with deactivated penetration stabilizer. Wire diameter: 1.2 mm; additional wire G3Si1; wire feed speed: 3.6 m/min. (Courtesy of Fronius International GmbH)
A new algorithm uses the high processing power, large memory, extremely fast system bus and highly dynamic wire feed speed of the latest MIG/MAG power source platform to ensure an extremely stable arc with minimal spatter.
Plasma Cutters

Beware of Bad Bargains

Counterfeit replacement parts are often sold at prices about 30 percent or more below the price of the genuine parts. 
Watch out for artificially low prices on aftermarket plasma torch consumable parts. Before you buy, it is important to be aware of a few of the poor performance issues and risk of torch damage that your shop will experience if you purchase imitation consumables.
Power Sources

The Pride of the Pipeline

Manual welding with a PipeWorx 400 multiprocess power source that does RMD and Pulsed MIG welding. Changeover is quick because there is no need to manually switch polarity or cables and hoses between processes. Welders can also trigger through pre-set programs while at the welding joint to eliminate walking back and resetting the machine.
By changing welding processes, this oil and gas production equipment manufacturer has cut more than 200 man-hours out of each product and is thriving on the shale gas boom.
Resistance Welders

Seamlessly Joined? Comparing Cast and Soldered Electrodes for Spot Welding

Figure 1. This photo of the micro sections of a soldered electrode insert clearly shows the cavities at the joint between the base of the WL20 electrode and the copper shaft.
Cavities in the solder between the electrode and the shaft have a negative impact on the quality of the resistance weld. Plansee explains why anyone wishing to avoid cavities should use cast electrodes rather than soldered electrodes.
TIG Welders

Field of Dreams

High Tech Welding has gained 25 to 30 percent in productivity in its field repairs since it began using the Multimatic 200 a year ago. The portability and multiprocess capabilities of the unit are at the heart of those benefits.
Take a look at how Wisconsin fabricator High Tech Welding uses a portable all-in-one multiprocess power source to gain versatility and increase their welding productivity by 25 to 30 percent on field repair and fabrication jobs.
Welding Gloves

From Selection to Storage: The Basics of Common Aluminum Filler Metals

From trailer fabrication to shipbuilding and aerospace applications, companies rely on aluminum for its versatility, its strength and, in certain service environments, its corrosion resistance.(Click on photo to enlarge it)
In order to gain the best results when welding aluminum, Tim Hensley of Hobart Brothershere are the reasons why and how it is critical to select the correct filler metal and carefully follow the proper storage and handling procedures for these products.
Welding Guns/Torches

Fume Extraction Guns: What to Know for the Best Performance

Knowing some basic details about fume extraction guns, as well as good technique for using them, can help welding operators gain the best performance from this equipment. 
Knowing some basic details about fume extraction guns, as well as good technique for using them, can help welders gain the best performance from this equipment. 
Welding Helmets

Improving Welder Safety and Comfort with New Head Protection Technologies

A PAPR is a powered air purifying respirator paired with a welding helmet that uses a blower to pass ambient air through a high-efficiency particulate air (HEPA) filter to remove contaminants and supply purified air in a sealed welding helmet. This removes at least 99.97 percent of airborne particles 0.3 micrometers in diameter.
Recent technology advancements in welding helmets not only help to protect welders from lost-time or work-related injury, but they increase productivity by increasing comfort levels. Regardless of the type of head protection a welder chooses, it is critical to make sure that the helmet, PAPR or other such personal protective equipment (PPE) is properly suited for the welding application at hand and also provides the appropriate level of protection.
Wire Feeders

Automated Welding Increases Productivity

Joy Mining's plant in Franklin, PA, produces longwall and continuous miner systems that are distributed all over the world.(Click on photo to enlarge it)
The Franklin plant of mining equipment manufacturer Joy Mining increased productivity and reduced costs in their bit block assembly by converting to automated welding systems from The Lincoln Electric Company.
Welding: Products

Portable Welding & Cutting Just Got More Portable

Weighing only 18 lb, the MiniArc 161LTS is an extremely portable, 115V or 230V, single-phase machine that provides outstanding results for GTAW (TIG) and Stick welding, and is able to use cellulosic 6010 electrodes with ease. 
The lightweight, highly portable MiniArc161LTS power source for GTAW/Stick welding and PowerCut® 400 manual plasma cutting system systems from ESAB are ideal for transport on or offsite as the job demands.

Flux-Cored Wire Offers Low Hydrogen (H4) Weld Deposits, Superior “As-Welded” and PWHT Properties

FabCO 712M wire features a fast-freezing, easily removable slag that makes it suitable for all-position welding and minimizes interpass and post-weld cleaning. It also provides a tensile strength of 83 ksi in the as-welded condition and 80 ksi after PWHT.
FabCO 712M gas-shielded flux-cored wire from Hobart Brothers is ideal for offshore drilling rig applications and jack-up rig fabrication.

Pipeline Welding & Fabrication

The consistent and repeatable weld quality of new orbital welding systems reduces weld defects to achieve high productivity rates, and meets the harsh demands of environmental conditions to reduce field serviceability and downtime. (photo courtesy of Lincoln Electric) 
As the need for specialty steel pipe grows, higher steel grades and bigger wall thicknesses are introducing new challenges to pipe welding and fabrication shops. Here are some of the latest advances in welding equipment and fabrication tools that can help these shops gain and maintain a competitive advantage.
Events Calendar
September 15 - 17, 2014
San Diego Convention Center -- San Deigo, CA
September 15 - 17, 2014
Guangzhou International Mould & Die Exhibition, China Import and Export Fair Complex -- Guangzhou, China
September 16 - 18, 2014
Houston, TX
September 17, 2014, 10:30am - 11:30am
Webinar Hosted by Burr Oak Tool, Sturgis, MI
September 17 - 18, 2014
John S. Knight Center -- Akron, OH