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).

Step-by-Step Improvements: Understanding the Value of Advanced Welding Information Management Systems

To achieve big cost savings, quality improvements and productivity enhancements, advanced data management systems can manage and control almost any factor – before, during and after the actual welding process.
Experts
Automation/Robotics

How to Improve Robotic Welding Production

Understanding the fixed costs and the variable costs in each step of the process is an important step for increasing throughput in robotic welding. Once these have been identified and measured as key cost drivers, that information can be used to decide where to focus attention for improvement efforts to get the biggest impact. 
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.
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

Navigating OSHA’s Hierarchy of Controls to Minimize Weld Fume

Managing weld fumes is important for compliance with increasingly strict exposure limits from agencies such as the Occupational Safety and Health Administration (OSHA) and the American Conference of Governmental Industrial Hygienists (ACGIH).
In considering which weld fume management solution is right for your shop environment, be aware that it may be necessary to implement multiple solutions from the agency’s outlines to achieve the desired exposure limits for each individual metal, metal oxide or gas found in the weld plume. Here are the steps to follow. 
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

Tips for Proper Liner Installation to Help Optimize MIG Gun Performance

Improper liner installation — which includes trimming the liner too short or having a liner that is too long — can lead to a number of problems, such as birdnesting, wire feeding issues and increased debris in the liner. These issues can result in costly rework and operator downtime for maintenance and repairs, which impacts productivity.
MIG gun consumables are often one of the most overlooked portions of the welding operation. However, choosing the right consumables, and using and maintaining them properly, can make a significant difference in gun performance and weld quality.
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.
Welding: Products

Advanced, Spatter-Free Welding in Aluminum and Stainless Steel

To achieve high deposition rates, the Aristo® Mig 4004i Pulse delivers a welding current of 300 A and voltage of 32 V at a 100 percent duty cycle. At a 60 percent duty cycle, these figures rise to 400 A and 36 V. The machine operates from a 380 to 460V (+/-10 percent), three phase supply at 50/60Hz, and can be powered by a generator when there is no mains supply available.
The Aristo® Mig 4004i Pulse power source from ESAB is ideal for manufacturing trucks, buses, trailers, off-highway equipment, trains and railway rolling stock, wind turbine towers, structural steelwork, shipbuilding/offshore, and general industrial fabrication.

Centricut Consumables for ESAB PT-36 Torches

The patented SilverLine electrode features a hybrid copper / silver weld joint that delivers performance equal to a solid silver electrode for a fraction of the cost. Advanced cooling features reduce its operating temperature to maximize the hafnium pit depth and slow its wear rate to extend electrode life. CoolFlow technology improves cooling to help maintain the size and shape of the nozzle orifice for longer life. 
These new electrodes and nozzles replace the original XR consumables in the torch and are guaranteed to perform as well as the ESAB units.

MIG Push-Pull Welding System Packages

This synergic welding power offers features single-control setting of simple weld parameters, while at the same time offering access to advanced waveforms and processes developed to deliver enhanced appearance and heat input control on aluminum, including Pulse-on-Pulse® and Power Mode®.
The POWER MIG® 350MP Push-Pull System from Lincoln Electric is ideal for trailer manufacturing, and its One-Pak® package targets aluminum automotive collision repair and fabrication.