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).

The Pride of the Pipeline

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.
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 Flux-Cored Wires

Both gas-shielded and self-shielded FCAW wires can provide higher deposition rates than solid wire or stick electrodes and are relatively easy to use, making them a more productive filler metal choice for many applications. 
As with any filler metal, welders must weigh out the advantages and disadvantages of gas-shielded and self-shielded FCAW wires to determine if these are the best choice for their specific application.
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

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.
Plasma Cutters

This is Not Your Grandfather’s Plasma Cutting System

The plasma cut cleanly and quickly through 1/8 inch metal, just as simple as drawing a line. 
My previous experience with plasma cutting happened 30 years ago and was so awful that I never wanted to use one again. I vowed then and there to never use plasma again. Then I used one of the new units from Hypertherm.
Power Sources

How Electronic Fuel Injection Technology Improves Efficiency of Engine-Driven Welding Power Sources

Electronic Fuel Injection (EFI) has been used for decades and is standard in many cars, but it’s a technology that’s fairly new to the smaller engines used in gasoline-powered engine-driven welding power sources. Incorporating EFI technology results in reduced emissions and provides numerous other benefits in welding and construction applications, including increased fuel efficiency.
As contractors and welders continually look for ways to reduce welding costs and be more efficient, things as simple as engine choice can make quite a difference.
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

Checking the Pulse of Welding Inconel

Inconel, as many nickel-based alloys, is highly susceptible to cracking and warping – especially thin structures. As such, controlling heat input to the part is important, as well as controlling arc starts, providing proper shielding gas protection and averting crater formation at the end of the weld.(Click on photo to enlarge it)
Whether TIG welding in the aerospace industry or MIG welding overlay in a plant environment, successfully welding Inconel can depend on your pulsing capabilities and other new features made possible with modern equipment. Dave Almy and Mark Kadlec of Miller Electric explain why.
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

Robotic MIG Gun Options that Improve Quality and Reduce Downtime

The wire brake and air blast features shown on this robotic MIG gun are available as factory-installed options or they can be retrofitted. 
The wire brake and air blast can be used together or separately to help improve quality and performance in robotic MIG gun applications, leading to cost savings for welding operations. 
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

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.

Wireless Pedal for TIG Welding Applications

The Wireless Pedal makes it easier to access hard-to-reach areas. The receiver features an LED display that indicates the status of foot pedal battery life, welding output and signal integrity. It also includes a power cable adapter requiring 115V service. Extension legs adapt the pedal for use at an angle or on irregular surfaces.
The K3127-1 Wireless Pedal from Lincoln Electric reduces clutter and improves workplace safety by eliminating cords that can lead to tripping hazards in the shop environment.

Reality-Based Welding Training System Builds Welding Careers

The new LiveArc™ reality-based training system is designed to recruit, screen, train and manage welding trainee performance — all via a live welding arc. (first view)
Ideal for vocational schools or fab shops, the LiveArc™ Welding Performance Management System from Miller Electric recruits, screens, trains and manages welding trainee performance via a live welding arc by using advanced motion-tracking technology for critical feedback to improve welding skills and provide better, faster, more cost-effective results than traditional training methods.