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).

Gaining Efficiencies by Increasing Welding Wire Size

The time and energy it takes to make the conversion from smaller-diameter wire to a larger one could save countless hours and improve quality. Here are several initial steps that are necessary to make the conversion.
Experts
Automation/Robotics

Tube Water Wall Overlay

American Electric Power gained a definite financial advantage by purchasing their own overlay motion control equipment from Bug-O Systems and hiring local labor to perform the operation. 
Engine Driven Welders

Next Generation Speed Governing Technology

Numerous benefits can be gained from improved fuel efficiency and reduced noise when using new welder/generators with speed-regulating technology.
Filler Metals/Electrodes

Tips for Taking the Trouble Out of Aluminum Welding

Here are some tips on how to maintain exceptional cleanliness, select the right filler metal and employ the correct welding preparations to remove the oxide layer on the surface of the material.
Fume Extraction Systems

Navigating OSHA’s Hierarchy of Controls to Minimize Weld Fume

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

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

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

The Next Big Thing in Sheet Metal Fabrication

The competitive advantages of laser welding are generating all sorts of excitement as new advancements have minimized the initial investment required and offer a more affordable entry for job shops. 
MIG Welders

New Arc Process for More Efficient Welding

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

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

How Multiprocess Welders Address Heavy Fabrication Challenges

The combination of new engineering with improved and reliable current technology for single source TIG, MIG and/or Stick welding and carbon arc gouging can really increase the operating profitability of jobsites and fabrication shops.
Resistance Welders

Seamlessly Joined? Comparing Cast and Soldered Electrodes for Spot Welding

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

The Passion Inside Out Back

A father-son boat repair and fabrication shop finds power, flexibility and quality with a TIG welder that can deal with the unique challenges of their business.
Welding Gloves

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

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

Insider Q&A: Questions Answered About Water-Cooled Robotic MIG Guns

Using either air or water to keep a robotic MIG gun cool is critical because it protects the components from damage due to radiant heat from the arc and resistive heat from the electrical components in the welding circuit. These insights will help you determine if a water-cooled gun is the best fit for your application.
Welding Helmets

Improving Welder Safety and Comfort with New Head Protection Technologies

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

A New State of Flux

The unique Integrated Cold Electrode technology for submerged arc welding applications from ESAB can substantially increase productivity while exceeding critical welds requirements by exploiting the excess heat from the Twin SAW process to melt an additional non-powered welding electrode. This doubles the productivity in deposition rates and in root welds when compared to single wire welding. (First view)
Take a look at how these new submerged arc welding systems meet the demands of heavy fabrication, shipbuilding, pressure vessel, beam fabrication, wind tower and pipe manufacturing.

Big on MIG

(Photo courtesy of Instructables)
Equipment reviews of some of the newest MIG welding systems and accessories for the shop, the field, and for home hobbyists.

Set and Forget” Welding Helmet

The exclusive Adaptive Shade Autopilot automatically adjusts the e684 ADF to the appropriate shade level as one welds. Its third sensor helps the e684 immediately detect changes in arc intensity and adjusts accordingly. This allows welder to stay focused on what really matters: striking the perfect arc.
With fully automated shade level protection, Adaptive Shade Autopilot ADF technology automatically adjusts the shade level on this helmet to the welder's parameters in full high definition viewing.