Consumables Articles

The devil is in the details, especially when it comes to welding processes. This technology area has information on consumables, including cutting tips, electrodes and wire, spatter prevention compounds, temporary purge dams, and welding torch components.

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Consumables Corner: Understanding welding heat input and its effects on base materials

March 28, 2016

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What guidelines should a job shop follow in regards to heat input if there is no welding procedure to fall back on? The Consumables Corner team has the answer.

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What’s inside your GTAW torch?

March 16, 2016

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Welders are judged by the appearance of their beads, the strength of their welds, and their ability to pass visual and technical inspection. So why shouldn’t you scrutinize your GTAW torch components in the same way that you or someone else would scrutinize your welds? If your GTAW torch doesn’t pass inspection, there’s a good chance that your welds won’t either.

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Consumables Corner: Selecting the right welding process and filler metal for repair work

January 29, 2016

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The Consumables crew assists a reader tasked with repairing a tower crane.

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Consumables Corner: Discovering the cause of lack of fusion in PJP joints

November 16, 2015

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Q: We manufacture various products for the agriculture and transportation industries. A majority of our products are made from 6061 and 5652 aluminum and are joined with gas metal arc welding (GMAW-S) using a 5356 filler metal and 100 percent argon shielding gas. Most of the joints are partial...

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Consumables Corner: Welding medium-carbon to high-strength steel

September 28, 2015

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Q: We need to weld a 1-in.-thick AISI 1050 carbon steel plate to a 2-in.-dia. A514 steel shaft. The AISI 1050 has a yield and tensile strength of 95 KSI and 115 KSI, respectively. We know we should preheat, but we're unsure of what temperatures to use or what filler metal to select. Could you...

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Shielding gas blends for carbon steel GMAW

September 28, 2015

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Argon and CO2 are the most commonly used gases in gas metal arc welding (GMAW). Alone, each has pronounced advantages. Together they combine to neutralize each other’s weaknesses and capitalize on each other’s strengths, all while providing you with your desired weld requirements.

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Selecting the right contact tip size

September 24, 2015

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Using the right-sized contact tip is critical to achieving optimal results in robotic and semiautomatic GMAW operations. Among the factors that determine the right tip size are the process and wire.

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Consumables Corner: Welding dissimilar metals using 309 stainless steel

July 27, 2015

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The Consumables Corner team counsels a company struggling with weld fusion when joining ferritic to carbon steel.

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Getting to Know Flux-cored Wires

July 15, 2015

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Flux-cored wires have unique welding characteristics and requirements, advantages, and limitations. Knowing these can help in determining whether they are the right choice for your application.

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Using cored wire in submerged arc welding applications

June 11, 2015

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Like all arc welding processes, submerged arc welding (SAW) requires the right consumables for the specific application to achieve optimal results. Are cored wires right for yours?

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Consumables Corner: Eliminating weld cracking in restrained joints on high-strength steel

May 12, 2015

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Q: We're a construction equipment manufacturer that is finding that our customers increasingly require more components designed and manufactured from high-strength steels such as A514 or 4130. This means we have to preheat and follow slow cooling conditions, but even then certain joints or...

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Consumables Corner: The right filler metal to weld duplex stainless steel

March 16, 2015

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Q: We manufacture stainless steel tanks used in various industries and we aren’t always informed of service conditions and chemical exposures. We would like to reduce or minimize the number of filler metals we use to cut down on costs and prevent accidental use of the wrong filler metal. The...

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Consumables Corner: Causes of centerline cracking in FCAW root passes

January 20, 2015

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Q: We are a bridge and structural steel manufacturing shop that uses a mixture of common base materials such as A36, A572, and A992. Recently we’ve been experiencing sporadic centerline cracks in the root passes of fabricated I-beams that we weld with flux-cored arc welding (FCAW). Oddly enough,...

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Consumables Corner: Understanding heat input and its limitations

November 21, 2014

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Q: We manufacture structures for the utility industry and primarily weld A36, A572-Gr. 50 and A871-Gr. 65. Recently we converted some of our welding processes to higher-deposition submerged-arc welding (SAW) but are concerned about the amount of heat we are adding from welding. What is the...

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The case for consumables

November 21, 2014

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New-generation GMAW consumables reduce the number of components, eliminate threads in the electrical path, and feature gas ported contact tips that run cooler and can accommodate more wire in a single tip.

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